Mechanical Section Comments

Subject: CCC "CONSTRUCTION COMPLETION CERTIFICATE" DOCUMENTATION –

OUTSTANDING ISSUE ITEM NO 25 -

DISCREPANCIES IN CCC DOCUMENTATION- MECHANICAL SECTION

Reference: Contractor’s email dated October 19, 2018

Review of scanned CCC (Construction Completion Certificate) documentation regarding

Mechanical Works provided by HEI-HRL JV up-till 19.10.2018, has revealed discrepancies
which are required to be addressed expeditiously as noted below:-

1- Firefighting System (CCC#1,CCC#2)

(1) RFI for painting on joints of steel structure columns and beams is required to be
provided.(RFI has not been raised by HEI)
(2) All Installation RFI,sand test reports of firefighting system i.e welding reports, hydro-
test reports of Admin Building, Hostels and Cafeteria are missing.(Uncommissioned
system)
(3) Installation RFI for one overhead refilling point of fire trucks is missing.(Need to
check with rehan)
(4) Installation RFI for placing of portable fire extinguishers at all plant site is missing.
(One RFI is already attached TEPC-HY-056 and O&M team also receive the fire
hydrant in presence of client ----Moreover, according to letter#1132 the comment#05
is in Progress-)
2- HVAC System (CCC#3):-
(1) RFIs for insulation and welding of chilled water supply and return piping need to
be provided.(RFIs are already been attached i.e. TU-370, TU-373)
(2) Installation RFI of VRF system in Admin Building, Hostels and Cafeteria is
missing. (Uncommissioned System)
(3) Approved MAS of HVAC Air Devices need to be provided.(Approved company is
YORK)
(4) Approved MAS of VRF System regarding Copper pipe and Insulation need to be
provided. (MAS is already provided to Nespak not returned to HEI)
(5) Installation RFI for Aluminum Louvers in Air compressor Building need to be
provided.
(6) RFIs for GI duct installation and GI duct alignment in Mechanical service building,
Chemical lab, CCB, Switchyard control building, Administration Building, Steam
Turbine, Gas turbine and Hostels available with HRL/HEI need to be
provided.(available and will be attached later)
(7) RFI for GI duct Light Test in Mechanical service building, Chemical lab, CCB,
Switchyard control building, Administration Building, Steam Turbine, Gas turbine
and Hostels available with HRL/HEI need to be provided. (available and will be
attached later)
(8) RFI for all air devices installed at GI ducts need to be provided. (available and
will be attached later)
(9) RFIs for installation of HVAC Equipments, all AHUs installed in plant and Chillers
need to be provided. (The point is similar to the point#02)
 Mechanical Section Comments

3- Circulating water System (CCC1,CCC2,CCC#3):-

(1) RFI for painting on joints of steel structure columns and beams is required to be
provided. (RFI is attached with the reference of comment No.)

4- Closed Cooling Water System (CCC1,CCC2,CCC#3):

(1) RFI for painting on joints of steel structure columns and beams is required to be
provided. (RFI is attached with the reference of comment No.)
(2) HEI is required to submit rectified RFI for rejected Weld joint numbers 262,
264,269, 275, 23, 284, 312, 259, 09, 20 of CCCW system. TEPC Document: TEPC-
WE-111.
(3) HEI is required to submit rectified RFI for rejected Weld Joint Numbers 267, 313,
272 of CCCW system. TEPC Document: TEPC-WE-112.

5- Chlorination Plant (CCC#3):

(1) RFI for painting on joints of steel structure columns and beams is required to be
provided. (RFI is attached with the reference of comment No.)
(2) RFI for Piping Installation need to be provided.

6- Pipe Rack(CCC#1):-
(1) RFI for painting on joints of steel structure columns and beams is required to be
provided. (RFI is attached with the reference of comment No.)

7- Cranes (CCC#1,CCC#2,CCC#3):
(1) RFIs for installation of all cranes are not attached. (RFI is attached with the reference
of comment No.)

8- Oily Waste water Treatment System (CCC#1):

(1) RFI for Installation of Equipment is required to be provided. (RFI is attached with the
reference of comment No.)
(2) RFI for painting on joints of steel structure columns and beams is required to be
provided.

9- Fuel Gas system (CCC#1):

(1) In the provided folder of fuel system, Test reports and RFIs related to other systems i-
e EDG, HRSG, Nitrogen generation system, Compressed air system etc are
Attached. HEI is required to separate these reports and attach in the relevant file.
(RFI is attached with the reference of comment No.)
(2) RFI for Installation of Steel Structure in fuel gas station need to be provided.
(3) Welding Report for fuel gas piping system need to be submitted. (RFI is attached with
the reference of comment No.)
(4) Approved MS and ITP for the said system need to be provided. (RFI is attached with
the reference of comment No.)
 Mechanical Section Comments

10-Nitrogen generation system (CCC#1)

(1) RFI for painting on joints of steel structure columns and beams is required to be
provided. (RFI is attached with the reference of comment No.)
(2) Welding joints inspection reports of nitrogen piping to be submitted.
(3) Air blowing inspection reports of nitrogen piping.
(4) Provide the hydro test inspection details and RFIs of nitrogen gas piping.
(5) Method statements of the nitrogen generation system need to be attached.

11-Compressed air system (CCC#1):

(1) RFI for painting on joints of steel structure columns and beams is required to be
provided. (RFI is attached with the reference of comment No.)
(2) According to approved ITP No HEI-Bhikki-QCP-C-ME-04 dated 26.08.2018, RFIs
related to hydro test packages, inspection prior to pressure testing, Restoration of
system after complete testing have not been attached.
12-Hydrogen Generation System (CCC#1, CCC#2):
(1) RFI for painting on joints of steel structure columns and beams is required to be
provided.
(2) RFIs for Welding joints of hydrogen generation system need to be provided.
(3) RFIs for supports and hangers of hydrogen piping need to be provided.
(4) Approved Method Statement for the said system need to be provided.
13-Chemical water Treatment System (CCC#1, CCC#2):
(1) RFI for installation of sanitary waste water and industrial waste water treatment
pumps need to be provided.
(2) Water Tight Test Reports shall be provided for Gates installed in Bio Ponds and
MBR tanks.
(3) Installation RFI for Removable Handrail in waste water lifting station need to be
provided.
(4) Installation RFI(s) need to be provided for Sludge feed pumps, sludge dehydrator&
Sludge mixers. (RFI is attached with the reference of comment No.)
(5) RFI for painting on joints of steel structure columns and beams is required to be
provided. (RFI is attached with the reference of comment No.)
(6) Approved ITP for chemical water treatment system is missing. (RFI is attached with
the reference of comment No.)

14-Fuel Oil System (CCC#1):

(1) RFI for painting on joints of steel structure columns and beams is required to be
provided. (RFI is attached with the reference of comment No.)
(2) Installation RFI for Oil Unloading Modification system is missing.

15-EDG (CCC#1):
(1) Installation RFI need to be provided.
(2) RFI for painting on joints of steel structure columns and beams is required to be
provided. (RFI is attached with the reference of comment No.)

17-Steam Turbine (CCC#3):

 Mechanical Section Comments

1. RFI for painting on joints of steel structure columns and beams is required to be
provided.(RFI not found)
2. Approved ITP&MS shall be attached. (RFI is attached with the reference of
comment No.)

18-Gas Turbines (CCC#1, CCC#2):

(1) RFI for painting on joints of steel structure columns and beams is required to be
provided.(RFI not found)
(2) Approved ITP need to be provided. (RFI is attached with the reference of comment
No.)
19-HRSG (CCC#3):
(1) Method Statements TEPC-GL-A08-002, TEPC-GL-A08-003, and TEPC-GL-A08-004
are in Chinese language and without signature of NESPAK in the provided folder.
HEI to provide the same in English language bearing NESPAK signature. (This
document is HEI internal no need nespak to review )
(2) RFI for painting on joints of steel structure columns and beams is required to be
provided.(Refer to AN-425, AN-402, AN-514, AN-515)
(3) Hydro test Package of HRSG #2 is not provided and need to be submitted. Only
HRSG#1 is found.(Test Report is attached with reference of comment No.)
(4) Inspection Reports # TEPC-TU- 507/508 bearing Nespak signatures shall be
provided.(RFI is attached reference of comment No.)
(5) Approved Copies of WPS-PQR relating to HRSG welding is required. (Documents
are attached with reference of comment No.)
(6) Complete HRSG Stack Welding Record is to be provided. (Documents are attached
with reference of comment No.)
(7) Method Statement for Insulation of HRSG need to be provided. (Documents are
attached with reference of comment No.)
(8) Complete Insulation inspection record for HRSG Piping, Stack and ducts is required
to be provided. (Documents are attached with reference of comment No.)
(9) As per provision of ASME Code Section I, Master Data report and P3-P4 Forms
required. (Documents are attached with reference of comment No.)
(10) HRSG Name plate drawing indicating MWAP required to be provided.
(Documents are attached with reference of comment No.)
(11) NDT Procedures essentially required to be submitted prior to the following tests
shall be provided; (Documents are attached with reference of comment No.)
1-Radiographic testing 2- Ultrasonic testing 3- Magnetic testing4-Positive
material identification test/spectral analysis 5-Hardness testing
(12) HRSG safety Valves data sheet shall be provided. (Documents are attached with
reference of comment No.)
(13) Partial manufacturer data reports signed by ASME Inspector available with
HEI, are required. (Documents are attached with reference of comment No.)
(14) A complete Inspection record of Steam Blowing need to be provided.
(Documents are attached with reference of comment No.)
(15) HRSG Elevator's 3rd party inspection record is required.(RFI not found ---Need
to contact gulzar for RFIs)
 Mechanical Section Comments

(16) Partial manufacturer reports for HRSG Safety valve are required to be provided.
(Documents are attached with reference of comment No.)
(17) Method statement and Complete Inspection record for Chemical Cleaning of
HRSG is required. (Documents are attached with reference of comment No.)