1.

FINAL PROJECT RECORD BOOKS

1.1. As per GEMSS-G-10-Rev01 Submittals, as a

minimum the Contractor shall provide the following
drawings as applicable with respect to the type of
the plant:

Description

GENERAL DOCUMENTS (applicable to all plant)

CONTRACT MANAGEMENT DOCUMENTS

a. Contract Programme

b. Project organisation and personnel (including charts)

c. Health and safety management plan

d. Quality/Inspection and Test Programme

e. Project quality plans

f. Sub-contractor/vendor lists

g. Purchase orders (un-priced) for main plant equipment

h. Inspection and testing procedures/reports

i. Spares lists – Contractual and recommended spare parts

j. Special tools list

k. Plant numbering and nomenclature

l. Plant labelling and identification

m. Painting Specification

j. List of Applicable Codes and Standards

k. Hazardous area classification drawings

l. Hazid/Hazan/Hazop studies and reports

 Description

m. Terminal point schedules and drawings

n. Certification of pressure systems and lifting equipment
o. Site testing, commissioning procedures and records
p. Preventative maintenance schedules
q. Operating and Maintenance Manuals

r. As-built/record copy drawings and documents

s. Drawing number philosophy
t. Environmental management project plan for plant construction and operation until
PAC
u. Waste management plan
v. Training programme

w. Site Security Plan

x. Loss Prevention Programme
PLANT OPERATION/PERFORMANCE

a. Performance Test Procedure and Test Records

b. Heat and mass balance diagrams for the full range of operating cases

c. Auxiliary power listing

d. Unit power output and efficiency correction curves

e. Unit power output and efficiency degradation curve verses operating hours (recovery
after each overhaul shall be shown)
f. Unit start-up/shut down curves for hot, warm and cold starts. These must include
cumulative fuel consumption and cumulative MWh generated/imported for each type of
start and shutdown
g. Noise data and test procedure

PLANT AND SYSTEMS (AS APPLICABLE)

2.1 BOILER / HRSG (IF APPLICABLE)

a. Technical specification and description of boiler equipment and auxiliary systems

b. General arrangement drawings and sections of boiler/HRSG and auxiliary equipment

c. Feed pumps specification and performance calculations

 Description

d. Schematic diagrams (P&IDs), descriptions and data of boiler systems (flue gas/CEMS,
water/steam, drains)
e. Pressure part code calculations

f. Draft and air balance calculations

g. Lagging and insulation specification

2.2 STEAM TURBINE / GAS TURBINE (AS APPLICABLE)

a. Technical descriptions, general arrangement drawings and sections of steam turbine
gas turbine equipment and auxiliary systems
b. Turbine hall layout, (including GTs) and space for laydown/access

c. Steam turbine/Gas Turbine specification

d. Steam turbine/Gas Turbine governor and lube oil systems data

e. Steam turbine/Gas Turbine calculations and performance curves

f. Schematic diagrams (P&IDs) and descriptions for ST / GT systems (lube and control
oil, water/steam cycle, drains)
g. Condenser technical descriptions, general arrangement drawings and sections

2.3 SCR (If Applicable)

a. Technical descriptions, general arrangement drawings and sections of SCR
equipment, including of catalyst, Urea/Ammonia storage, vessels, blowers, heaters, air
mixer and injection balancing skid
b. Details and calculations of NOx removal method, including slip
c. Technical descriptions, general arrangement drawings and sections of FGD equipment

d. Details and calculations of sulphur removal method

e. Absorber, bypass damper, steam pre-heater and sulphate removal system data and
drawings
GENERAL MECHANICAL

a. Equipment list
b. Valve list
c. Termination point schedules and drawings
d. Pipework schedules and layouts
e. List of lubricants
f. Specifications, characteristic curves for all major pumps
 Description

AUXILIARY SYSTEMS AND EQUIPMENT (AS APPLICABLE)

System Descriptions and Diagrams (P&IDs), terminal point schedules and drawings,
operating/performance data and arrangement drawings for the following systems and
equipment:
a. Water supply system (desalination and demineralization plant), including water
balance, interfaces with existing plant and arrangement of demineralized plant,
demineralized water storage tank data and drawings
b. Waste water system, including emissions monitoring concept
c. Fuel oil systems HFO, HCO and DFO, including unloading, storage and fuel transfer
facilities, data, equipment specifications, calculations and drawings (as applicable)
d. Steam turbine condensing and feed-water systems, including arrangement drawings,
description and specification data, characteristic curves and rating calculations for
condenser, condensate extraction pumps, and boiler feed pump systems
e. CW intake system data, equipment specifications, calculations and drawings, including
optimization studies for CW system
f. Closed circuit cooling (CCCW) system heat exchanger data and drawings, circulating
pump curves and drawings
g. Water supply system (desalination and demineralization plant), including water
balance, interfaces with existing plant and arrangement of demineralized plant,
demineralized water storage tank data and drawings
h. Waste water system, including emissions monitoring concept
i. Fuel oil systems for HFO, HCO and DFO, including unloading, storage and fuel
transfer facilities, data, equipment specifications, calculations and drawings
j. Chemical dosing system data, equipment specifications and drawings
k. Electro-chlorination plant data, equipment specifications and drawings
l. Gas systems (H2/CO2/N2) data and drawings
j. Sampling systems data, equipment specifications and drawings
k. Emission monitoring system (CEMS) data, equipment specifications and drawings
l. Fire detection and protection system data, equipment specifications and drawings
m. Service air system data, equipment specifications and drawings
n. Instrument air system, including compressor operating/performance data and
arrangement
o. Cranes and Lifting equipment, including steam turbine cranes

ELECTRICAL SYSTEMS AND EQUIPMENT

 Description

a. General arrangement and sections for steam turbine/Gas Turbine generators and
excitation equipment
b. Generator excitation schematic diagrams, and interfaces with plant control system
c. Characteristic and capability curves for generators
d. Curves for generator transformers including over excitation curve, loading capability
e. Transformer drawings showing lead exit support, arrangement and dimension of
windings, fixing arrangement for core and coil to tank and lid, yoke clamping
f. Schematic arrangement for axial split and radial split winding for power transformers
g. General arrangement of generator transformers, common auxiliary transformers, unit
and auxiliary transformers
h. Layout drawings showing arrangement of all equipment in transformer compounds and
enclosures
i. General arrangement of MV and LV switchboards
j. Layout drawings showing arrangement of all electrical equipment in switchgear rooms,
battery rooms, cable rooms
k. Transient overvoltage study for MV circuit breakers
l. Protection diagram for all main circuits
m. Descriptive technical information on protective relays
n. Single line diagrams for all AC and DC systems
o. Schedule of electrical equipment for hazardous areas
p. Schematic diagram of synchronizing scheme
q. Design data, specifications and calculations for DC and UPS systems
r. Design calculations, schedules and drawings, including connection and termination
drawings of the cabling system
s. Design, calculations and drawings of the earthing and lightning protection systems
t. Short circuit load flow and motor starting calculations
u. Calculations to confirm nominal ratio and tapping range of transformers
v. Insulation co-ordination study
w. Phasing diagram including transformer vector groups
x. Instrument transformer calculations
y. Control and interlocking logic for MV and LV switchgear
z. Protective relaying co-ordination study
aa. Design, calculations and drawings of lighting and small power installations
 Description

bb. Specification, operational criteria and sizing calculations for emergency diesel
generator sets
cc. Operating and maintenance instructions for all electrical equipment

I&C SYSTEMS

a. Design and operation philosophy

b. Functional design specification
c. Graphics functional design specification
d. Alarm philosophy
e. Tripping/shutdown philosophy
f. DCS description and configured logic diagrams
g. ST/GT governor and load control description and logic diagrams
h. AVR and PSS description, block control diagram
j. DCS thermodynamic model
k. Details of plant conditioning monitoring system
l. Aqueous and gaseous emission monitoring philosophy and equipment details
m. Technical descriptions and data sheets
n. Hazardous area data
o. Instrument data sheets
p. Instrument schedule
q. Alarm schedule (including data logging/information inputs) and alarm management
philosophy
r. Input/output schedule (including serial data)

s. General arrangement drawings

t. Equipment layout drawings

u. Installation drawings

v. Specification and design data for communications equipment

w. Power supply philosophy

x. I&C earthing philosophy

y. Specification and design data for site security system

z. Wiring diagrams and schematics

 Description

aa. Cable connection/termination drawings

bb. Interface diagrams

cc. Software listings

dd. Commissioning procedures

ee. Functional test procedures

ff. Performance test procedures

gg. Hardware test specification

hh. Software test specification

ii. Factory acceptance test procedures

4.1 MICROPROCESSOR BASED SYSTEMS

a. Operation and control philosophy
b. Control and protection system details
c. Menu guide to control system facilities
d. Description of all sequences in a structured step-by-step format
e. Printed error message guide
f. Alarm message guide
g. Brief description of any hardware back-up features
h. Process parameter values under normal operating regimes
j. Hardware trouble-shooting guide
k. Instructions for changeover from remote to local control and vice-versa
l. Plant configuration and database listing
m. Plant operating system listing
n. User-configurable software listing
o. System error messages listing
p. Trouble-shooting guidelines
q. On and off-line diagnostic software
r. Communications network management software
s. Hardware list and system diagrams
t. Start-up instructions for all hardware
u. Listing of system error messages
 Description

v. Description of links or interface hardware between vendor control packages and DCS
w. I/O card listing identifying location and function

PLANT LAYOUT/CIVIL

a. Site layout drawings, showing the position of all buildings and major plant items,
external works, roads and infrastructure, paving, yard works, fencing, etc.
b. Contractors proposed laydown/working areas and site establishment.
c. Civil and structural design concept report, including design criteria for the whole works.
d. Detailed design and construction programme.
e. Site survey and investigation proposals and reports (Volume 1: See Section 9.2.1)
f. Setting out and site datum details.
g. Working drawings and all supporting calculations for all buildings and structures, listed
in Volume 1: Section 3.1.4. and including but not limited to the following (all drawings
and calculations to be fully and clearly presented):

· Steam turbine foundations including analysis for dynamic effects

· Stack superstructure and foundations
· Boiler superstructure and foundations
· Steam turbine building superstructure and foundations
· CW system including intake channel, CWPH, seawater structures, supply
and discharge conduits and/or culverts etc
· All Off-shore works
· Transformer foundations
· Tanks and foundations
· All Ancillary buildings, superstructure and foundations
· Pipe racks structure and foundations
· Road layout and construction details, including pavement design
· Drainage systems and outfalls
· Building permit approvals
· Method statements for items of construction (submitted to Site
Management Team)
1.2. Content
The Final Technical File record is drawn up by the Contractor and intended for the
client. It shall contain all the documents related to:

· The manufacturing and construction of the Power Plant;

· The operation and maintenance of the Power Plant.

· All documents shall have the “As built” status.

· All the files, chapters and sections have their own table of contents.
· The CD or DVD or other IT media must be organized according to a tree
structure: the titles of the different parts (chapters etc.) and the files must
enable the users to find the document or the plan they are looking for very
rapidly.

1.3. The final documentation should be organized as

follows (Contractor may propose another table of
content which must include at least the items listed
in the following Chapter 1 – Chapter 11):
Chapter 1: Table of contents

The table of contents will refer to the folder number in which a chapter or
document can be found. It shall give a clear overview of the files.

Each folder, each chapter and each heading shall contain its own table of
contents.

Chapter 2: Usage notice of the records

A short note, if necessary illustrated with examples, describing how to use the
final documentation on how to get quick access to the information.

Chapter 3: Documents related to the order

3.1. Contract or purchase order of the Client:

Remark: The general contractual documents, such as "General

Conditions", "Worksite Regulations", etc., are not included in the final
documentation.

3.2. Specifications and technical data sheets:

Remark: When required by the construction code, specifications shall be

certified as compliant with the code and updated to "as built".

Chapter 4: Documents related to design

4.1. Documents list:

List of all Contractors’ documents issued for the project to the Client that
should indicate for each document:
· Title of the document;
· Identification number, status, revision;
 · For each revision the reference and date of the dispatch to the Client;
· For each revision the acceptance date and status.
All documents in the documents list have either a status of "As Built" or
"Final" at the time of the final presentation of the final documentation
(including for all documents made by sub-contractors).

4.2. Drawing list:

List of all Contractors’ drawing issued for the project to the Client that should
indicate for each document:

· Title of the drawing;

· Identification number, status, revision;
· For each revision the reference and date of the dispatch to the Client;
· For each revision the acceptance date and status.

All drawings in the drawing list have either a status of "As built" or "Final" at
the time of the final presentation of the final documentation (including for all
documents made by sub-contractors).

4.3. Drawings and electrical diagrams:

It contains a copy of all the drawings, folded in A4 format. When required

by the construction code, the drawings will carry an approval stamp of the
Recognized Inspection Authority. This part shall also contain all the
electrical wiring and terminal diagrams.

4.4. Data bases:

Contains the “Technical data sheet file”. It contains information such as

number, brand, name, etc. of all equipment. Contains other data bases
such as cable lists, I/O lists, line lists, valve lists...

4.5. Design documents:

Includes design documents (structural design, earthquake design, thermal

design, hydraulic design, HVAC design, piping stress analysis, supports,
acoustical studies, etc.) accompanied by any computer printouts;

All functional and descriptive documents;

When required by the application code the "Client's Review" form is

attached;

4.6. Various study documents:

Contains the documents not included in the other specific headings of this
Chapter 4.

4.7. Exceptions:

List of exceptions obtained and the content of each one;

4.8. Compliance certificates:

Release certificates at the end of shop manufacturing, different conformity

certificates as imposed by the contractual documents, reports of
compliance to the applicable regulations.
 Some certificates may only be signed on the approval of the final
documentation itself.

4.9. Qualification records:

It contains the procedures and qualification reports of equipment tested at

particular working conditions, not covered by a design calculation (radiation
endurance, earthquake, short circuit, soil tests, topographic documents,
special weld certification, etc.).

Chapter 5: Documents related to procurement

5.1. List of subcontractors

Gives, for each subcontractor, his details (name, complete address, etc.),
supplied equipment or services and the reference to his final documentation
under 5.2;

5.2. Records of the subcontractors

Organized identical to the final documentation. Chapters such as 3.2

(Specifications), would be documentation of the contractor. In case of sub-
contractors who supplied only raw materials, the structure may be simplified
by not applying certain headings (e.g.: 4.1, 4.2, 4.3, etc.).

Chapter 6: Documents related to manufacture

6.1. Manufacturing, quality and welding procedures

6.2. Quality plans:

Contains all signed-off quality plans of the contractor with reference to the
applicable drawing or procedure, the intervention (hold) points, credentials
of managers and controllers as well as the references of reports and any
non compliances of the operations.

6.3. Non compliance reports

6.4. Reports:

Quality reports referred to in the quality plans (non destructive tests,

resistance tests, soil tests, implantation controls, etc.).

6.5. X-ray films and other test welding control files

Chapter 7: Documents related to erection on site

Test procedures, test reports, incident reports, calibration certificates,

certificates.

Chapter 8: Documents related to start-up tests and commissioning

Test procedures, test reports, incident reports, calibration certificates,

certificates of commissioning and operation…

Remark: the reports of a Recognized Inspection Authority (required for

electrical equipment, fire detection and protection systems, steam
generators, cranes…) shall be classified in chapter 11.

Chapter 9: Documents related to the operation

9.1. Functional documents

Functional description of the delivered equipment, P&ID’s, operating

procedures, (periodical) control programs, procedures for isolating and
putting equipment in safe state, instructions for training of operators.

All functional and descriptive notes and the functional diagrams of the
Protection Systems.

9.2. Operation manual:

The Contractor shall supply complete and detailed Operating and

Maintenance manuals in English covering the operation and maintenance
of the plant and equipment as required by the Contract. The manuals shall
cover all the plant, associated auxiliaries and interface information supplied
under the Contract and shall contain all information necessary for safe and
economic operation and maintenance of the plant.

The contents of the operating and maintenance instructions, together with

all drawings, illustrations and diagrams shall refer specifically to the plant
and equipment being supplied under the Contract, and shall be specially
prepared where necessary. General instructions referring to a range of
equipment is not acceptable. Contents shall include all essential general
data and information, descriptive matter, operating instructions and
maintenance information necessary to enable the plant to be operated and
maintained properly and effectively.

Operating instructions shall detail all integrated plant normal pre-start

checks, starting up, running and shutting down procedures, for the various
modes of operation of the plant from cold, warm or hot conditions,
emergency operating procedures and any precautions recommended to
prevent plant deterioration during periods of non-operation. Operating
instructions shall cover local/remote and manual modes of operation and
shall also include action on receipt of alarms.

The Contractor shall prepare a comprehensive commissioning schedule for

each plant item and check lists to record the completion of these activities.
Copies of all settings and/or calibrations of instruments and controls,
pressure switches, trips and alarm settings confirmed and recorded in the
commissioning schedules shall be forwarded to be included in the
Operating Instructions.

Five sets of draft copies of the manuals shall be submitted to the Company
for review 6 months before commissioning commences. They shall be
submitted as complete texts. In the event that amendments or alterations
to the draft manuals are required, the Contractor shall submit revisions for
review without delay so that the final documents can be supplied within the
date specified. Eight sets of the final documents shall be submitted within
4 months after the Taking Over Certificate.

The whole of the operating and maintenance instructions shall be securely

bound in approved covers and provided with an index for easy reference.
 The O&M manuals shall be provided in paper hard copy and in electronic
copy on DVD or Hard Disk to a standard document reader format (i.e.
Adobe Acrobat Reader). The compilation of the electronic manual shall be
an exact replica of the bound manuals in all respects with all pages in
identical sequence and bearing the same page numbering.

The instruction manuals shall conform to the following format:

a) Index

The index system shall provide rapid and easy access to particular
subjects, drawings and illustrations. It should include a master
index and a sub-index to each main section of the manual.

b) Description

This section shall include basic data on the Plant.

i. Descriptions of the Plant both for individual items and for

the systems into which items are assembled.
ii. Drawings sufficient for the understanding of descriptions.
iii. Flow sheets or single line and block diagrams, which
explain the functioning and logic of the system. Where
related systems are shown on composite diagrams,
individual systems shall be identified by colour, or coding as
agreed.
iv. Schedules which assemble references to items of a
like/kind, eg valve schedules, piping schedule, operational
limit schedule, switchboard outline schedule, etc.
v. Data sheets which assemble in a concise format relevant
technical details of a plant item or system. The purpose of
a data sheet is to provide quick reference to the essential
facts omitting all reference to general descriptions,
operating or maintaining principles and instructions.

Chapter 10: Documents related to the maintenance

10.1. List of spare parts:

This section shall comprise the definite and optional spares as required by
the Company and the spares as recommended by the Tenderer. Details
and full ordering procedures for each item of main plant, auxiliary plant,
electrical and I&C equipment and vendor equipment and shall include:

i. Spare part lists together with referenced sectional drawings from

which the manufacturer’s descriptive name and part number can be
clearly identified for ordering purposes.

ii. Clear details of spare part supplier’s address, spare part ordering
procedure and including all appropriate plan item reference numbers
including serial numbers, type reference numbers, original order numbers,
etc as required for the immediate and correct supply of spare parts from
various original plant suppliers.
 iii. In this context the term “supplier’s address” means the sub-vendor or
original equipment manufacturer. It will not be acceptable for the
Contractor to nominate himself as the supplier of a spare part unless he
manufactures the particular equipment, or it is manufactured by a third
party in accordance with the Contractor’s own manufacturing drawings.

iv. A list of spares for each type of overhaul/inspection shall be provided.

v. Note: where spare parts are not available and full item replacement
is necessary this fact is to be advised and the appropriate ordering details
provided as defined above.

vi. For spares that are available from a multitude of sources (e.g. seals,
“O” rings, gaskets, nuts, bolts, etc. the Contractor shall supply details of
the sizes, standards and materials used.

vii. Details shall be provided of any special storage requirements or

limitations on storage life for spare parts.

10.2. Maintenance manual:

This section shall include the following:

viii. Build-up and assembly of systems and description of plant items.

ix. Schedule of equipment giving manufacturer’s name, the make/model

No/catalogue No and parts list including any special spares ordering
instructions. Spare parts catalogues shall be provided for the various
items of equipment supplied.

x. Routine maintenance schedule.

xi. Preventative maintenance and schedule of inspections.

xii. Details necessary to carry out overhauls.

xiii. Details necessary to locate and rectify faults.

xiv. Details necessary to set up, test and adjust plant systems and plant
items. To include as a minimum, fuel systems, carnage, ventilation,
fire protection, water treatment plant and compressed air equipment.

xv. Spares schedule.

xvi. Schedule of recommended lubricants.

xvii. Sectional drawings of major items of plant such as the steam

turbines, boilers, condensers, pumps, valves, electric generators,
transformers etc with dismantling instructions.
 xviii.As built copies of all relevant drawings corrected as necessary to
incorporate any late modifications.

xix. Plant layout drawing.

xx. Schematic diagrams and general arrangement drawings of “as-built”

control panels.

xxi. Wiring and cable diagrams.

xxii. Plant equipment and performance curves.

xxiii.Lifting gear register.

The final records shall include the construction and pre-commissioning

data dossier with signed record sheets.

It will also contain a synthetic maintenance program (periodicity of

maintenance).

10.3. Software:

Contains all documentation of the used software and the software

“licenses” (ex. operating system form PLC’S, etc) and a back-up of the
applicable software.

DCS and BPS programs: this part will contain the documents related with
the programming and the configuration (logic diagrams, functional
diagrams, control loops, Ethernet TCP/IP, Modbus communications)

A print-out of all the programs and a copy on disk or CD-ROM will be

handed over.

10.4. Data for O&M Maintenance System

All databases (equipment list,…) necessary to feed the O&M Maintenance

System shall be provided under native format, ready to be uploaded in the
O&M system.

Chapter 11: Document related to HSE (Health, Safety and Environment)

The final and complete set of reports concerning design safety risk
assessment (process hazards and operability, risk analysis…);

Safety instructions for maintenance and operation;

Operation and Maintenance training manual that shall provide information

about residual H&S risks and measures to be taken to control them;

An inventory of all used Man Made Vitreous Fibers (MMVF) or Synthetic

Vitreous Fibers (SVF);
MSDS (Medical Safety and Data Sheets) documents for used hazardous
products;

Inventory of hazardous products specifying the volume used and location;

Contractor’s Declaration of Conformity;

Certificate of compliance with all applicable requirements, rules, standards

and regulations;

Start-up certificates of Recognized Inspection Authorities Including an

inventory of equipment requiring periodic recertification;

List of fire fighting and detection equipment;

Final Explosion safety assessment for the scope of supply in the framework
of the Hazardous Areas classification , including drawings with identification
of hazardous explosion areas;

Drawings and lists with the identification of the equipment (and its category)
of which the design, manufacture and conformity assessment has to
conform toHazardous Areas classification;

Eexi / Eexd certificates will be included in this part.