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UPPER ZAKUM 750


ISLANDS SURFACE FACILITIES PROJECT – EPC2
PROJECT No. P7512

PUNCH LISTING PROCEDURE

Doc. No. P7512-PB-2000-G-0046 Rev. B1 Page: 2 of 18

TABULATION OF REVISED SECTIONS / PAGES

Revision Page / Section Description


Punch item numbering terminology amended
12 / 6.15
to this section.

TABULATION OF HOLDS

Page / Section Description


UPPER ZAKUM 750
ISLANDS SURFACE FACILITIES PROJECT – EPC2
PROJECT No. P7512

PUNCH LISTING PROCEDURE

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Table of Contents

1. PURPOSE.......................................................................................................................................... 4

2. SCOPE ............................................................................................................................................... 4
3. DEFINITIONS/ABBREVIATIONS..................................................................................................... 4
4. REFERENCES .................................................................................................................................. 5
5. RESPONSIBILITY & AUTHORITY .................................................................................................. 6
6. DESCRIPTION OF ACTIVITIES ....................................................................................................... 7

6.1 GENERAL ................................................................................................................................ 7


6.2 PUNCH LIST CLASSIFICATION ............................................................................................. 7
6.3 PUNCH LIST RESPONSIBILITY AT YARDS ......................................................................... 8
6.4 PUNCH LIST CATEGORIZATION .......................................................................................... 8
6.5 PUNCH LISTING PHASES ...................................................................................................... 8
6.6 HYDROSTATIC OR PNEUMATIC TESTING PUNCH LIST ................................................... 9
6.7 FAT PUNCH ITEMS ................................................................................................................. 9
6.8 YARD PUNCH ITEMS ........................................................................................................... 10
6.9 MECHANICAL COMPLETION WALK DOWN ...................................................................... 10
6.10 READY FOR COMMISSIONING WALK DOWN ................................................................... 10
6.11 PRE SAFETY START-UP REVIEW....................................................................................... 10
6.12 POST WALK DOWN PUNCH LIST RESOLUTION PROCESS ........................................... 10
6.13 DEFINING PUNCH LISTING BOUNDARIES ........................................................................ 11
6.14 PUNCH LISTING NOTIFICATION ......................................................................................... 11
6.15 PUNCH LIST RECORDING ................................................................................................... 11
6.16 PUNCH LIST REVIEW, MONITORING, AND TRACKING ................................................... 13
6.17 PUNCH LIST CLEARING AND ACCEPTANCE ................................................................... 13
6.18 DISPUTED/ DISAGREED PUNCH ITEMS ............................................................................ 13
6.19 REJECTED PUNCH ITEMS ................................................................................................... 13
7. RECORDS ....................................................................................................................................... 14
8. APPENDICES .................................................................................................................................. 14
UPPER ZAKUM 750
ISLANDS SURFACE FACILITIES PROJECT – EPC2
PROJECT No. P7512

PUNCH LISTING PROCEDURE

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1. PURPOSE

This procedure defines a structured approach and the standard requirements for tracking
repair defective items necessary for the completion of systems/sub-systems and for the
subsequent handover of the FACILITY from Construction to Commissioning and to
Operations (COMPANY)

2. SCOPE

This procedure describes the standard work process for controlling punch list items where
CONTRACTOR is responsible for Construction, Pre-commissioning and Commissioning in
both Yards & Islands.

Punch listing is to be performed prior to the transfer of responsibilities for a system/sub-


system from one stage to another for the purpose of care, custody and control.

3. DEFINITIONS/ABBREVIATIONS

The following are definitions for key terms used in this document:

COMPANY ZADCO
Petrofac Emirates and Daewoo Shipbuilding and Marine
CONTRACTOR
Engineering COMPANY
Drawing or document amended to reflect the final installation as
As Built
Constructed, Pre-commissioned and Commissioned.

A listing of defects, omissions, damages, or discrepancies that


have been observed and recorded during inspections resulting
from joint Company-Contractor system walk downs or as
otherwise observed by either party following completion of
scheduled construction or commissioning scheduled inspection
Punch List and testing programs.

Note: Outstanding work that has open checks and inspections (check
sheets) covering the outstanding work scope is not to be regarded as
a punch list item (i.e. incomplete "work to go" is not to be punch listed
if it has open check sheets related to the "work to go").

The sub-system has been constructed in accordance with the


Mechanical specifications and ‘IFC’ drawings and all walk down punch list
Completion category ‘A’ items have been completed.

The sub-system has been functionally tested and Pre-


commissioned in accordance with the CONTRACT and the Pre-
Pre-Commissioning
Commissioning check sheets and review of Punch list items.
Completion
Category B items must be closed prior to Handover stage and
Category “C” items must be closed prior to provisional
Acceptance. However, Punch list items will be closed as much
UPPER ZAKUM 750
ISLANDS SURFACE FACILITIES PROJECT – EPC2
PROJECT No. P7512

PUNCH LISTING PROCEDURE

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as possible at the earliest stage

The system has been functionally tested (Except for


hydrocarbon systems) and commissioned in accordance with
Commissioning
the CONTRACT and the Commissioning procedures and
Completion
CONTRACTOR confirmed that all B punch items must be closed
prior to Handover

It is the stage upon successful Commissioning, when


CONTRACTOR considers the whole or the relevant part of the
PLANT to be in a condition for handover to the care, custody
Handover
and control of COMPANY. CONTRACTOR shall so notify
COMPANY and shall request the issue of a HANDOVER
CERTIFICATE

Abbreviations used:

IFC Issued For Construction


AT Factory Acceptance Test
HSSE Health, Safety, Security and Environment
NCR Non Conformance Report
PL Punch List
RFC Ready for Commissioning
RFI Request for Inspection
PSSR Pre-safety start-up review
HO Handover to Operation (Company)

4. REFERENCES

The following documents are used as source of reference and may be read in conjunction with
this procedure.

Contract requirements
 Part IV Exhibit Z.38 - Acceptance
 Part IV Exhibit Z.50 - Mechanical Completion and Commissioning
Planning and Documentation
Project documents

 P7512-PB-2000-G-0037 - PetroPCS Set-Up and Implementation Procedure


 P7512-PB-2000-G-0049 - Handover Procedure
 P7512-GD-2000-G-0039 - System Completion Plan
 P7512-GD-2000-G-0022 - Systemization Procedure
UPPER ZAKUM 750
ISLANDS SURFACE FACILITIES PROJECT – EPC2
PROJECT No. P7512

PUNCH LISTING PROCEDURE

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5. RESPONSIBILITY & AUTHORITY

Responsible for the overall implementation of this procedure, including the


Yard / Field Project
required coordination and support between functional groups and
Manager /
departments assigned to the project.
Yard / Field Construction
He is also responsible for assigning field engineers to participate in walk
Manager
downs and check/approve the completion of punch list items.

Responsible for the proper implementation of this procedure and assigning


Commissioning engineers to participate in walk downs ensuring that all
Project Commissioning
deficiencies and repairs on systems/sub-systems are captured and
Manager
entered into PetroPCS. He is also responsible for ensuring that priorities
and system/sub-system completion dates are identified and achieved.

Responsible for participating in the walk downs to ensure that all


deficiencies and repairs plus all check sheets are completed or excepted
Commissioning Engineer
are captured and entered into PetroPCS. He is responsible for assigning
priority to the punch list item(s) and signing them off when complete.

Responsible for assigning and coordinating punch list item work to be


completed and ensuring that the work is carried out according to the pre-
Construction Engineer
determined schedule. He is responsible for assigning, coordinating and
scheduling punch list item work with the SUB-CONTRACTOR.

Responsible for participating in walk downs, identifying and/or indicating


the completion of a punch list item.
Yard / Field Engineer &
QA/QC Engineer QA/QC shall also identify the outstanding FAT Punch items which cannot
be closed at factory and handover to Punch list coordinator therefore to
update PetroPCS.

Responsible for generating, approving and signing off completed punch list
COMPANY
items. COMPANY shall have the “WRITE” access to verify all the Punch
Representatives
items in PetroPCS Software.

Responsible for coordinating with the Punch List Coordinator to establish


COMPANY Lead
validity and classification of punch items at each stage of progression of
Commissioning Engineer
the project completion.

Responsible for monitoring the readiness of systems/sub-systems in


PetroPCS for walk downs at the different stages of the project completion
Turnover Coordinator
(as detailed in section 6.4). He is also responsible for initiating the walk
downs by submitting an RFI to all concerned parties.
UPPER ZAKUM 750
ISLANDS SURFACE FACILITIES PROJECT – EPC2
PROJECT No. P7512

PUNCH LISTING PROCEDURE

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Reports to Turnover Coordinator, responsible for coordinating the walk


down and maintaining punch list items data integrity in PetroPCS. The
Punch list coordinator is the gatekeeper for verifying the legitimacy of
punch list items as defined Section 2 and section 6.13 of this document, in
consultation with COMPANY, before they are entered into PetroPCS,
categorizing them in accordance with Para 6.2 of this document and then
issuing regular status reports to the site team throughout the various
Punch list Coordinator phases of the project. He will ensure that any out of scope, Add-on, and
changes will not be handled as punch items as it will required change
orders. He will also be responsible for coordinating with COMPANY Lead
Commissioning Engineer for reclassification of punch items at each stage
of the project completion.

Responsible for entering, editing, updating and maintaining data in


Turnover Operator
PetroPCS. On a daily basis to ensure timely updates within PetroPCS

6. DESCRIPTION OF ACTIVITIES

6.1 GENERAL

Prior to the transfer of responsibilities for a System/Sub-system, a check shall be done by


CONTRACTOR to verify that the scope of work for the System/Sub-system is completed in
accordance with the design, project specifications, project procedures, and any other
contractual requirements. The checks shall also consist of physical walkthrough and
checking of all relevant installations within the identified System /Sub-system limits.

The checks consist of:

a) An assessment that all tasks have been completed. This is achieved through a review
of all documentation in the System/Sub-system handover package; i.e. check sheets,
QA/QC reports, testing sheets, vendor reports, etc. for accuracy and completeness, and
that all inspection and test requirements have been carried out as specified in the
relevant procedures.
b) Review of the “As Built” drawings to verify that they reflect the actual build in the field
including a “red line” mark up of all the changes or modifications.
c) Verification that the System/Sub-system conforms to all project requirements.
6.2 PUNCH LIST CLASSIFICATION

Punch list items shall be classified according to their degree of impact on HSSE, equipment
integrity, and subsequent scheduled activities. The assignment of punch list classification
shall be agreed between CONTRACTOR Construction, CONTRACTOR Commissioning and
COMPANY Projects and Operations.
 Category “A” Punch: Must be completed prior to Mechanical completion. It signifies that
the punch list item, defect, missing item, or omission is deemed critical such as those
which prevent safe operation of plant, equipment, system and may jeopardize personnel
UPPER ZAKUM 750
ISLANDS SURFACE FACILITIES PROJECT – EPC2
PROJECT No. P7512

PUNCH LISTING PROCEDURE

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& or equipment and must be repaired without which the next activity cannot be
undertaken safely. This category shall also include points that cannot be attended to at
a later stage of the project
 Category “B” Punch: Must be completed prior to Handover (Ea System). It signifies that
the punch list item, defect, missing item, or omission which will not affect the safe
progression of the System /Sub-system to the next stage
 Category “C” Punch: Must be completed prior to PROVISIONAL ACCEPTANCE, or as
soon as practicable thereafter in accordance with a schedule to be agreed with
COMPANY. These punches should not affect the safe operation of the System /Sub
system

6.3 PUNCH LIST RESPONSIBILITY AT YARDS

All Punch list items identified in the Yard and not completed in the Yard will be subject to
the same classification stipulated in section 6.2. However the Punch list items not
executed in Yard prior to module transportation, and thus required to be undertaken post
module arrival at Island, must be agreed at Yard by CONTRACTOR, FABRICATION
CONTRACTOR and COMPANY and the cost of the defect repair will remain the
responsibility of the FABRICATION CONTRACTOR after the transportation of the module
from the Yard to the Island.

Load out certificate does not represent that Yard obligation to close Punch list items has
been either discharged or waived.

6.4 PUNCH LIST CATEGORIZATION

 Upon generation of punch items, CONTRACTOR and COMPANY will identify the re-
categorization code of the generated punch items during Pre-Commissioning and
Commissioning phases and update them on the punch list form (Refer 8.1 Appendix A –
Blank Punch list).
 When a sub-system is progressed from one stage to the other, the turnover coordinator
will automatically update PetroPCS to reflect the new category of the punch item based
on the agreed re-categorization codes.
 Refer Section 8 Appendix C – Punch Listing Flow Chart

6.5 PUNCH LISTING PHASES

Punch list items may be raised, reviewed, and resolved throughout the life of the Project. A
formal inspection and verification assessment shall be carried out on System/Sub-system
level at the following phases of the project:
 Prior to hydrostatic or pneumatic testing of pipe work
 Outstanding FAT Punch items which cannot be closed at factory
 Punch items outstanding from Yard
 At Mechanical Completion handover phase prior to issuing the “Sub-System Mechanical
Completion Certificate”
 At Pre-commissioning stage prior to issue “Ready for Commissioning certificate”.
UPPER ZAKUM 750
ISLANDS SURFACE FACILITIES PROJECT – EPC2
PROJECT No. P7512

PUNCH LISTING PROCEDURE

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 Commissioning stage prior to issue “Commissioning Completion Certificate”.


 Prior to Handover all required “C” category punch items to be identified.

Figure 1 – Punch listing phases

Punch items shall also be captured during the Pre-Start-Up safety audit and resolved prior
to introducing hydrocarbons into the plant or prior to the Project Completion depending on
their effect on the safe operation of the FACILITY.

6.6 HYDROSTATIC OR PNEUMATIC TESTING PUNCH LIST

1. The primary objective of this punch list is to identify items which will jeopardize the well-
being of personnel and the integrity of the pipe work or equipment, if not corrected prior
to testing.

2. Second objective is to identify items that if not corrected prior to testing will result in re-
work and re-testing.

Following the re-instatement after the test, all outstanding items shall be consolidated and
transferred to PetroPCS, with each item classified in accordance with Para 6.2 of this
document and entered into the PetroPCS Database.

6.7 FAT PUNCH ITEMS

All the punch items that are originated from factory shall be cleared prior to shipment to the
Yard/Island. However, some items cannot be closed during factory and these items shall be
identified by Quality Control Team and categorized as A, B or C with the entity responsible for
closure identified and loaded in to PetroPCS. These items must be closed out at the earliest
opportunity. COMPANY/CONTRACTOR Commissioning manager shall agree on the
outstanding FAT punch items that cannot be closed at yard prior to sign the Ready for Load
out Certificate.
UPPER ZAKUM 750
ISLANDS SURFACE FACILITIES PROJECT – EPC2
PROJECT No. P7512

PUNCH LISTING PROCEDURE

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6.8 YARD PUNCH ITEMS

Yard punch items shall be tracked and closed as specified in this document and all
referenced documents. In addition, any punch items that remain open at time of load out,
shall be clearly identified as an attachment to the "Ready for Load Out " certificate and
include categorization and entity responsible for closure.

6.9 MECHANICAL COMPLETION WALK DOWN

When all Construction ‘A’ check sheets have been completed for a sub-system and loaded
into PetroPCS, CONTRACTOR shall notify COMPANY for a joint walk down prior to issuing
the “Mechanical Completion Certificate”. Each discipline representative records
discrepancies and non-conformances found during the walk down. The Punch List items
shall be categorised in accordance with section 6.2 of this document and recorded in the
PetroPCS database.
The Mechanical Completion Walk down will verify that Mechanical Completion has been
sufficiently progressed so as to move into Pre-Commissioning phase.

All ‘A’ punch list items for Sub-System Mechanical Completion stage of the project shall be
cleared before the “Sub-System Mechanical Completion Certificate” is issued.

6.10 READY FOR COMMISSIONING WALK DOWN

When all Pre-commissioning B check sheets have been completed for a System/ Sub
system and loaded in to PetroPCS, CONTRACTOR shall notify COMPANY for a joint walk
down to issuing the “Ready for Commissioning Certificate”. The Punch List items shall be
categorized in accordance with section 6.2 of this document and recorded in the PetroPCS
database.

6.11 PRE SAFETY START-UP REVIEW

A system safety review shall be conducted at Systems’ Commissioning Completion prior to


issuing the “Commissioning Completion Certificate”

When all Commissioning ‘C’ check sheets have been completed for a system and loaded
into PetroPCS, CONTRACTOR shall notify COMPANY for a joint walk down. The Punch
List items shall be categorised in accordance with Para 6.2 of this document and recorded
in the PetroPCS database.

6.12 POST WALK DOWN PUNCH LIST RESOLUTION PROCESS

Punch List coordinator shall arrange a walk down close out meeting within 24 hours to verify
the legitimacy and agree the categorization of punch items after each walk down. Any
disputed items shall be verified and agreed prior to handover the punch list to PetroPCS for
data entry.
UPPER ZAKUM 750
ISLANDS SURFACE FACILITIES PROJECT – EPC2
PROJECT No. P7512

PUNCH LISTING PROCEDURE

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6.13 DEFINING PUNCH LISTING BOUNDARIES

All inspections and verifications shall be made against the latest revision IFC, P&IDs, PFDs,
SLDs, isometric drawings and relevant discipline standards, specifications, and checklists.
The boundaries for verification of the physical works are defined in the system/sub-system
identification marked up drawings which shall be attached to the walk down notification.
Verification shall not include components, equipment, etc outside these boundaries.

Punch items will be limited to not installed as per IFC drawings, defective items & items that
pose a safety hazard to personnel or may lead to unsafe operation of the plant and shall
not include “preferential engineering” items.

Significant observations regarding the design of the facilities made during walk downs
should be treated as either Non-conformance if not built as per specification with NCRs
issued by Company, or if additional requirements are identified above the base scope,
treated as Contract variations. In either case, these design observations should not be
loaded as punch items as they do not meet the definition of a punch list item (see section
2.0).

6.14 PUNCH LISTING NOTIFICATION

Upon readiness of a system/sub-system for a walk down, as detailed in Para 6.3, the
turnover coordinator shall issue a “Request for Inspection” (RFI) to the concerned parties for
any one of the phases listed in Section 6.3 of this document. When issuing an RFI,
CONTRACTOR shall provide sufficient notice (Five Days) to all concerned parties to ensure
that the required resources are available at the time requested. Minimum requirements for
names of walk down participants must be agreed at the time of RFI issue and the walk down
shall be rescheduled if any required participant is missing. Therefore, it is important that key
walk down personnel be available and where necessary any alternates pre-agreed. The
notice shall include all relevant documentation with the boundaries of the inspection clearly
indicated and Punch List for the subsystem with the current close out status. If deemed
necessary and agreed in between COMPANY & CONTRACTOR walk down for a particular
system / sub-system may be split up as per discipline.

A “Request for Inspection” log shall be kept in the CONTRACTOR turnover office and shall
be used by all parties.

6.15 PUNCH LIST RECORDING

During all joint walk downs, as further defined in this document and exhibit Z.38, a
"nominated punch items recorder" shall be named prior to the walk down. During the walk
down and immediately following the walk down, all punch list items from all participants are
to be consolidated on the master punch list. The master punch list will then be reviewed
within 24 hrs jointly with participants to agree punch item categorization. These meetings
will be termed "agreement meetings". Where punch item categorization cannot be agreed,
then the punch item in question shall be elevated to Commissioning/Completions leads and
when necessary Commissioning/Completions Managers for assignment of category. The
escalation process for all punch listing disputes must be agreed prior to beginning walk
UPPER ZAKUM 750
ISLANDS SURFACE FACILITIES PROJECT – EPC2
PROJECT No. P7512

PUNCH LISTING PROCEDURE

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down process." In addition, the "Master Punch List" shall be generated by Contractor and
approved by Company for each walk down.

FAT / Yard pending items shall be recorded in PetroPCS for further follow up. All punch list
generated during the handover from Construction Sub-Contractor to CONTRACTOR shall
be recorded and included with the RFI.

The Turnover Team is responsible for entering the punch items listed into the PetroPCS
database for monitoring and tracking purposes.

Subsequently, all deficiencies and non-conformances discovered during walk downs the
various phases described in section 6.3 shall be recorded and entered into the PetroPCS
Database or rejected. Rejected Punch items will be returned for submission as change
order.

The punch list shall contain the following:

 Sub-system Number
 Punch Listing Phases
 Date of walk down
 Punch List No.
 Originator Name
 Tag Number
 Material Required (Yes / No)
 Discipline
 Description of the deficiency
 Punch list item Category (A, B and C)
 Signature of CONTRACTORS Accepting Authority for closing out a punch item (Closure
will be tracked electronically in Petro-PCS. Clearing by CONTRACTOR, Verification by
COMPANY.).
 Signature Blocks for CONTRACTOR and COMPANY representative
 Walk down participants
A Blank Punch List Form is attached as Appendix A

Punch number will be given by Turnover Team as per the following numbering terminology
for the various Yards/ Islands

Eg: Punch item originate at GPC Yard shall start with “PL-GPC-0001”.

However, FAT punch items outstanding from across the manufactures will be loaded in to
PetroPCS in accordance with Par 6.7 and the numbering shall be start with “PL-FAT-0001”.
UPPER ZAKUM 750
ISLANDS SURFACE FACILITIES PROJECT – EPC2
PROJECT No. P7512

PUNCH LISTING PROCEDURE

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6.16 PUNCH LIST REVIEW, MONITORING, AND TRACKING

The Construction and Commissioning engineers shall regularly monitor the progress of
outstanding punch list items clearance and they shall plan/assign the priorities in line with
scheduled completion dates.

During punching it is conceivable that some punch items identified will require Engineering
review and action. The responsible engineer will communicate these punch queries to
Engineering for mitigation and subsequent corrective implementation at site.

The punch list coordinator will review the status of all punch list items and will closely follow
with the Construction and Commissioning engineers to complete punch list items that would
be deemed critical for releasing completion certificates at the different stages of the project
phase. The punch list coordinator will periodically issue a status report showing the balance
of all open punch list items to the Construction and Commissioning manager highlighting
priorities for their action.

6.17 PUNCH LIST CLEARING AND ACCEPTANCE

Resolution of punch list items shall be carried out by CONTRACTOR. Once the Punch list is
physically closed out in field, as per IFC drawings, CONTRACTOR will sign it off on the
original Project Punch List form and submit it to Turnover Operator to enter “Cleared date”
by CONTRACTOR in PetroPCS. COMPANY shall verify the punch item against IFC
drawings and the Accepted Date and the name of person who has accepted will be updated
in PetroPCS. If any rejected items will be treated as per Section 6.19 of this document

The responsibility for clearing punch list items shall rest with the CONTRACTOR
Construction unless these punch list items are agreed to be completed by CONTRACTOR
Commissioning or CONTRACTOR Commissioning requested that something within the
Construction work scope be left out to assist with the progression of the Commissioning
work scope; e.g., insulation flange or valve covers left off for a leak test, blind installed in a
closed position, etc.

The responsibility for accepting and signing-off cleared punch list items shall be the
responsibility of COMPANY for any punch list items generated in the PetroPCS. Also
COMPANY shall update in to the PetroPCS software for all punch list acceptance.

6.18 DISPUTED/ DISAGREED PUNCH ITEMS

Disputed punch item will be resolved before they are entered in to PetroPCS. They will be
resolved at the post walk down meeting between Sub-Contractor, Contractor and
COMPANY. If no agreement can be reached at that level then it will be escalated to
Management level for resolution

6.19 REJECTED PUNCH ITEMS

Rejected Punch items are a result of COMPANY not agreeing with CONTRACTOR that the
quality of the defect repair is adequate and the defect required further remedial action. If no
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agreement can be reached that the quality of the defect repair is adequate then it will be
escalated to Management level for resolution

7. RECORDS

Records are as shown in examples in the appendices. See also P7512-PB-2000-G-0037


PetroPCS Set up and Implementation Procedure.

8. APPENDICES

Appendix A – Punch List Form

Appendix B – Punch List Generation, Execution & Close-Out Flow Chart

Appendix C – Punch Listing Flow Chart

Appendix D – Disagreed / Disputed Punch Listing Flow Chart


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Appendix A – Punch List Form


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Appendix B – Punch List Generation, Execution & Closeout Flow Chart


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PROJECT No. P7512

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Appendix C – Punch Listing Flow Chart


UPPER ZAKUM 750
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PROJECT No. P7512

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Appendix D – Disagreed / Disputed Punch Listing Flow Chart