PROCEDURE NO :

PROJECT SPECIFIC PROCEDURE PSP-KPD-FAB-G6014

REVISION : A1
JACKET / TOPSIDES

MECHANICAL COMPLETION PROCEDURE

FOR

PC MURIAH LIMITED
CONTRACT NO. 5700000377
PTMI PROJECT NO. R3215

PROVISION OF PROCUREMENT, CONSTRUCTION,

INSTALLATION AND COMMISSIONING OF
SURFACE FACILITIES AND INFIELD FLOWLINE FOR
KEPODANG GAS DEVELOPMENT PROJECT

CONTRACTOR PCML
Rev Prepared By Reviewed By Approved By Reviewed By Approved By
Date
No. Name Sign Date Name Sign Date Name Sign Date Name Sign Date Name Sign Date
A1
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REVISION LIST

SECTION REV DATE DESCRIPTION OF AMENDMENT

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TABLE OF CONTENTS

SECTION DESCRIPTION PAGE

1.0 PURPOSE...............................................................................................4
2.0 SCOPE....................................................................................................4
3.0 REFERENCE DOCUMENTS.................................................................4
4.0 ABBREVIATION.....................................................................................4
5.0 DEFINITIONS.........................................................................................5
6.0 PROCEDURE.........................................................................................5
7.0 SPECIAL REQUIREMENTS (IF ANY)...................................................9
8.0 RECORDS..............................................................................................9
APPENDICES.........................................................................................1
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1.0 PURPOSE

The purpose of this document is to describe the process of construction completion to

achieve project mechanical completion stage for the PCML Kepodang Gas
Development Project. This procedure also provides a means to prioritize and sequence
the control of mechanical completion and facilitate a systematic means of project hand-
over to commissioning group. This procedure defines the activities, roles and
responsibilities of various groups/individuals involved in mechanical completion to work
towards common goal of maximizing onshore commissioning.

2.0 SCOPE

Mechanical completion activity shall be performed on all equipments in line with the
supplier’s recommendations and will include but not be limited to the following:
1. Mechanical Equipments (Static and Rotating).
2. Electrical Equipments & Bulks (Control Panels, Junction Boxes, Switchgears, etc).
3. Instrument Devices & Bulks (Transmitters, Detectors, Switches, Instrument Control
or Actuated Valves).
4. Piping Bulks (Pipes, Flanges, and Valves)

3.0 REFERENCE DOCUMENTS

This procedure shall be read in conjunction with the following:
PTMI Level 2 Quality Procedure
1. MDR-AP-BY-L2-FAB-203 : Fabrication Operation Procedure-Preservation
PCML Engineering Specification
1. KPD99-01-G-SPE-2003 : Preservation and Packaging of Equipment and Material
Specification
2. CSP-T20 :

4.0 ABBREVIATION

PTMI : PT McDermott Indonesia

PCML : Petronas Carigali Muriah Ltd

CPP : Central Processing Platform

WHTC : Wellhead Tower C

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ORF : Onshore Receiving Facility

VPI : Vapor Phase Inhibitor

5.0 DEFINITIONS

Supplier : Manufacture of the equipment

Contractor : PT McDermott Indonesia

Client : PC Muriah Ltd

Preservation : Periodic preventive maintenance activities are carried out on the

equipments and materials base on supplier’s recommendation
by preservation group.

Storage : Method to store the equipment and material during warehousing

by warehouse personnel and during temporary lay-down &
erection by construction group.

Protection : Material installed to prevent damage from external source. It will

be managed by PIC in all phases of construction.

6.0 PROCEDURE

 The condition of supplier preservation and protection of equipment and bulk

material shall be inspected against the supplier preservation sheet upon receipt on
PTMI fabrication yard. After inspection of equipment and bulk material any damage
to the preservation and protective medium shall be reported.

 A detailed storage and preservation procedure shall be provided by supplier as part

of dispatch dossier. PTMI shall use this supplier’s procedure as main reference
doing the handling, storage, and preservation.

 All major equipment shall have prominent notice indicating the method of
preservation and the date applied. Preservation Tag will be attached on major
equipment indicating the date of preservation has been done and assigned
technician.

 Stainless steel and other alloys bulk material shall be stored separately from carbon
steel items. Contact with carbon steel component shall be avoided.
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 Contact with standing water shall be avoided at all times. Where possible items
shall be stored with pallet or a concrete base.

 Major tagged equipment preservation activity will be recorded and reported. Bulk
material storage and protection is general practice guidance throughout fabrication
phase is not necessarily recorded and reported.

6.1 MECHANICAL EQUIPMENT

 Storage mechanical equipment is normally stored in locations free from

construction activity and where accidental damage is not likely to occur. Such
equipment shall be placed in dry area.
 All large pieces of equipment must be stored upright in a level attitude.
 In general, equipment is left in the original shipping cases and covered until ready
to be installed. Items requiring removal from shipping cases for identification or
renewal of protective coating should be returned to the cases until needed for
installation. Items such as covers removed for inspection, must be replaced and
secured in a manner to prevent leakage or loss.
 When the equipment is required for installation and where construction work is in
progress on and adjacent to the equipment in erection, the equipment shall be
protected against construction activities.
 Protection shall be installed to cover from weather and dirt. Covers over equipment
shall be placed in a manner so as to allow for air circulation. Flange opening, pipe
opening, tubing opening shall be blanked, plugged, and capped in all times.
 Should equipment remain in an exposed position for more than the supplier’s
allowed time, it should be disassembled, cleaned and the preservative renewed.
 Periodic visual inspection of stored equipment should be performed on the interval
time provided by supplier. Appropriate action shall be undertaken if found
necessary for the proper care of any item, and the customer mechanical engineer
shall be notified in writing.
 General rotating equipment internally protected with a lubricating oil base rust
preventative should be manually turned two or three revolutions. Care should be
taken that the final position of the shafts after turning is at least one quarter
revolution from the point at which rotation was started. Oil levels should be
checked at the time of rotation.
 Bearing housings should be filled to the bottom of the shaft/labyrinth bushings with
preservation oil for ball, roller and sleeve type bearings and pad type thrust
bearings.
 Internal uncoated surfaces of pressure vessel and atmospheric tank will be
protected against corrosion by fogging (spraying) with a lubricating oil base rust
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preventative or filling with an inert gas, depending on the nature of the service and
type of equipment.
 Equipment with internal protection installed should be tagged (red in color) stating
type of internal protection and location of same. This shall also be noted on the
equipment tags. This applies to both petroleum preservatives and desiccant.
 These procedures shall continue through storage, installation and up to test
running (pre-commissioning).

6.2 ELECTRICAL EQUIPMENT & BULK ITEMS

 Electrical equipment e.g. electrical panel, switchgears, junction boxes, light fittings,
motor, welding outlet, and socket outlet shall be stored indoor under
environmentally controlled room.
 Electrical bulks item e.g. cable, trays, shall be stored under covered area, dry and
free from construction activities. Cable shall be stored upright on drum with end of
cable sealed using heat shrink material or equivalent.
 Electric motors on equipment skid will be stored according to storage requirement
of the equipment skid.
 When the equipment is required for installation and where construction work is in
progress alongside the equipment in erection, the equipment shall be protected
against construction activities.
 Protection shall be installed to cover electrical equipment & bulks from weather,
dirt, and construction activities. Covers over equipment shall be placed in a manner
so it does not make any condensation and water trap.
 Motors are to be meggered upon receipt and again periodically during fabrication
periods up to construction completion. Any motors not meeting the Merger
specification are to be reported and dried out in accordance with the
manufacturer’s instructions.
 Irrespective of storage locations, heaters must be connected to the correct voltage
on motors, as instructed by the customer project electrical engineer.
 Care shall be taken to ensure that correct voltage is applied to space heaters. In
the event of space heater not being fitted, moisture absorbent gel bags are to be
placed inside panels etc. In addition, records are to be kept of insulation readings
on the preservation work sheet.
 Motor shafts are rotated at a frequency defined by Manufacturer, taking care to
ensure that the final position of moving parts is at least one-quarter revolution from
the position at start of rotation.
 All cable entries not used shall be suitably plugged.
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6.3 INSTRUMENT EQUIPMENT & BULK MATERIAL

 The pneumatic and electronic instrument devices, control valves, safety relief valve
shall be stored in air-conditioned or properly ventilated dry warehouse, i.e. where
the atmosphere is always above dew point.
 Large control valves and actuated valves may be stored outdoor under a shed roof
if necessary. Typically valves should be stored in vertical position. However, if a
valve is in a horizontal position, it must be store on a pallet rack.
 Instrument bulk material i.e. trays may be stored under cover and separate with
carbon steel items. Instrument tubing and fitting will be stored in door and shall be
separated with carbon steel items.
 Control Valve and Actuated Valves are to be stored in their rest position (no-
energy).
 Small amounts of desiccant or VPI should be placed in the instrument device
cases or shipping boxes. It may be necessary to seal both the instrument and the
desiccant in a plastic bag. Care should be taken so that the desiccant does not
contact any wiring or electronic parts.
 When the instrument devices are required for installation and where construction
work is in progress alongside the equipment in erection, the instrument devices
shall be protected against construction activities.
 Protection shall be installed to cover instrument devices & bulks from weather, dirt,
and construction activities. Covers over instrument devices shall be placed in a
manner so it does not make any condensation and water trap.
 Control valves and actuated valves body and flange faces shall be protected with
proper flange protection in all time since receiving, warehousing, erection, until
they are ready to be joined to line.

6.4 PIPING, FLANGES, FITTINGS, AND VALVES

 Piping and fitting (elbow, reducer, etc) may be stored outdoor, off the ground in
material lay down area. The principle to store the piping is stainless steel and other
alloy piping shall be stored separately from carbon steel items. Stainless steel item
will be covered with tarp and both end capped.
 Flanges and Valves will be stored indoor with exception for large flange & valve will
be stored outdoor, off the ground, and under tarp protection.
 Ball valves are to be fully open or fully closed during storage. Carbon steel valve
internal shall be coated with preservative oil.
 PTMI will verify all stainless steel and other alloy pipes, flanges, fittings and valves.
The warehouse will properly mark the pipe and fittings in order to keep the different
alloys separated.
 All stud and anchor bolts should be suitably stored & protected.
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 Flange faces (including valve flange face) shall be inspected all 100% of face
condition when arrived in receiving warehouse.
 Warehouse shall protect the flange face (including flange face faces) and put
lubricant and/or anti corrosion inhibitor soon after receiving inspection is
completed.
 Random checks shall be done to ensure the compliance of the requirements
throughout the warehousing period.
 During spool fabrication shop personnel shall put lubricant and / or anti corrosion
inhibitor and ensure flange face protection intact while fabrication in progress.
 During spool blasting and coating, production team shall protect the flange faces
and ensure flange faces in good condition prior to dispatch of spools to spool lay
down.
 Person in charge responsible for lay down area spool storage shall ensure the
fabricated spools are end capped and flange protected at all time.
 Air blow inside spool where necessary to remove any foreign materials prior
placing the end caps or flange protection.
 Fabricated spools upon arrival on the erection area shall be preserved by fitting
end caps or flange protections.
 Person in charge responsible for erection shall monitor and install pipe end cap,
valve protection and flange protection during construction fit-up of spools, valves,
fittings on top-side.
 After construction completed the hydrostatic test, flushing, and the furthermore
treatment will be captured by mechanical completion procedure or hydrostatic test
procedure.

7.0 SPECIAL REQUIREMENTS (IF ANY)

Special requirement and oil/grease/ rust preventive chemical recommended by supplier

will be highlighted on this section.

8.0 RECORDS

8.1 Preservation Record

PTMI will develop A Preservation Record containing the Major Equipment Tag No,
Initial Inspection, Initial Preservation, Preservation Period (schedule), and Activity
Code. The information on the required preservation activity and periodic requirement
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shall be based on the supplier information. A typical preservation record could be found
on Appendices 1.

8.2 Preservation Work Sheet

Preservation Work Sheet will be containing the inspection and activity required during
periodic preservation. The preservation work sheet will contain all activities required for
all major equipments. A typical preservation work sheet could be found on Appendices
2.

8.2.1 Mechanical Equipments

 Static Equipment: P01,P02,P03,P04,P05,P06,P07,P08,P09,P10,P11,P12,
P13.
 Rotating Equipment: P01,P02,P03,P04,P05,P06,P07,P08,P14,P15,P16.
 Skid Equipment: P01,P02,P03,P04,P06,P07,P08,P09,P10,P11,P12,P13,
P20

8.2.2 Electrical Equipments & Bulks:

 Control Panel & Junction Box: P01,P02,P03,P19,P04,P05,P06,P12,P13
 Motors: P17,P18

8.2.3 Instrument Devices & Bulks:

 Instrument Devices: P01,P02,P03,P06,P10,P11,P12,P13,P09,P20,P24

8.2.4 Piping Bulks (Pipes, Flanges, and Valves)

 Pipe, Fittings, and Spools: P01,P02,P21,P22,P23.

ACTIVITY ACTIVITY LIST DESCRIPTION SCHEDULE

NUMBER              
P01 Check overall condition of equipment. Report any discrepancy. MO
P02 Check that equipment is clean and free of refuse MO
Check that desiccants/vapor adsorbent chemicals are installed if
P03 recommended. Replace as required. MO
P04 Check for damaged paintwork MO
P05 Check that all bright metal surface are protected MO
P06 Check that equipment is protected from construction activities. MO
P07 Check protection of machined surfaces, flange faces, etc. MO
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P08 Check that all nozzles are properly covered / protected. MO

P09 Stroke and grease valve spindles and cover. 2MO
P10 Check that fragile parts of equipment are protected with covers. MO
Check that skid and non-skid mounted instrument and other
P11 equipment items are protected and lubricated as required. MO
Plug and/or tape-off unused holes and cable entry to prevent entry of
P12 dust and water. MO
Check sensitive electronic parts are free from moisture and water
P13 accumulation. MO
P14 Check preservation oil level if installed MO

P15 Check that rotary shaft and couplings are fully protected MO
P16 Rotate machinery shafting 2-1/4 turn MO
Check that anti-condensation heater or space heater is functional
P17 and energized if fitted MO
P18 Check insulation resistance windings and record 6MO
P19 Store sensitive equipment and panels in air-conditioned room MO
Check all instrument device covers and threads are lubricated and
P20 sealed as required. MO
P21 Check protection of bevel surfaces, flange faces, etc MO
P22 Check if end caps or flange protection is in place MO
Check warehouse or laydown area is suitable for storage of the
P23 material MO
P24 Check that instrument hook-up tubing and accessories are protected. MO
P25              
APPENDICES
 DOCUMENT NUMBER
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APPENDIX - 1
Page 1 of 4

Appendices 1. Preservation Record

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APPENDIX - 1
Page 2 of 4

Appendices 2. Preservation Work Sheet Page 1 of 2

 DOCUMENT NUMBER
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APPENDIX - 1
Page 3 of 4

Appendices 3. Preservation Work Sheet Page 2 of 2

 DOCUMENT NUMBER
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Appendices 3. Preservation Tag