Pre-Commissioning Manual

Document number
PRE-COMMISSIONING MANUAL YE-001-20-SOC-MAN-09261

Revision : 06 Status : IFC
Document Type : PRC System / Subsystem : 99 Discipline : PLR Rev Date : 10/04/08
Contractor document number : N/A Page 1 of 32
YEMEN LNG
Project
Pipeline
PRE-COMMISSIONING MANUAL
Rev. Status Date Revision memo Issued by Checked by Approved by
06 IFC 10/04/08 Issued for Construction. Modifications C.Umali P.Fernandez O.Balloy

applied on OPERCOM Form numberings.
M.Khaldi
05 IFC 10/10/07 Issued for Construction. Company C.Umali P.Fernandez O.Balloy
comments incorporated as per transmittal
T-PMT-751008 M.Khaldi

T-PMT-750961 M.Khaldi H.Mesa



T-PMT-750697 M.Khaldi
00 IFR 14/04/07 Issued for Review C.Umali P.Fernandez O.Balloy

M.Khaldi H.Mesa
This document is the property of Yemen LNG Company. It must not be stored, reproduced or disclosed to others without written
authorisation from the Company.
Document number
Table of Contents
1 INTRODUCTION............................................................................................................. 4
2 REFERENCE DOCUMENTS..........................................................................................4
3 DEFINITIONS AND ABBREVIATIONS...........................................................................4
4 SAFETY.......................................................................................................................... 5
5 RESPONSIBILITY...........................................................................................................5
6 PRE-COMMISSIONING METHODOLOGY.....................................................................6
6.1 SCOPE OF WORK AND ACTIVITIES......................................................................6
6.1.1 Conformity Check.............................................................................................6
6.1.2 Static / de-energized tests.................................................................................7
6.1.3 Piping Test (Test Pack).....................................................................................7
6.2 READY FOR COMMISSIONING (RFC)...................................................................8
6.3 STATUS INDEX.......................................................................................................9
6.4 PRE-COMMISSIONING PUNCHLIST......................................................................9
6.5 SEQUENCE OF EVENTS......................................................................................10
6.6 PRE-COMMISSIONING DOSSIER........................................................................10
7 PRE-COMMISSIONING PROCEDURES......................................................................10
7.1 EXCEPTIONS AND SPECIAL CASES..................................................................11
7.2 ELECTRICAL PRE-COMMISSIONING..................................................................11
7.2.1 Cables (Multicores/ multipairs, Field, LV Cables)............................................12
7.2.2 Junction/ Marshalling Box...............................................................................13
7.2.3 Earthing and Bonding......................................................................................14
7.2.4 Batteries.......................................................................................................... 14
7.2.5 Distribution Boards..........................................................................................15
7.2.6 Cable Trays.....................................................................................................16
7.2.7 Thermo Electric Generators (TEGs)................................................................16
7.2.8 Cathodic Protection System............................................................................16
7.3 INSTRUMENT PRE-COMMISSIONING................................................................16
7.3.1 Flow Element (Orifice Plate)............................................................................17
7.3.2 Control Valves and Accessories (Modulating).................................................17
7.3.3 Actuated Valves and Accessories (ESDV, MOVs, GHOVs)...........................17
7.3.4 Relief Valve.....................................................................................................18
7.3.5 Instrument Packages......................................................................................18
7.3.6 Instrument (Analog Input/Output)....................................................................18
7.3.7 Instrument (Switched/ Digital Output)..............................................................19
7.3.8 Instrument Tube/Pipe (Pneumatic, Impulse)...................................................19
7.3.9 Fire, Smoke and Gas Detection......................................................................19
7.4 MECHANICAL AND PIPING PRE-COMMISSIONING...........................................19
7.4.1 Mechanical Equipment Packages...................................................................19
7.4.2 KPU Gas Metering Package...........................................................................20
7.4.3 Vent Stack Package........................................................................................20
7.4.4 Pig Launchers, Pig Receivers.........................................................................20
7.4.5 NDT Clearance...............................................................................................20
Document number
7.4.6 Painting, Coating & Insulation for Piping.........................................................20

7.4.7 Pipework (Cleaning & Gauging, Pressure Test, Dewatering, Drying)..............20
7.4.8 Pressure Testing of Valves.............................................................................22
7.4.9 Bolt Tensioning and Torqueing.......................................................................22
7.5 TELECOMMUNICATIONS PRE-COMMISSIONING..............................................22
7.5.1 Fibre Optic Cable............................................................................................22
7.5.2 SCADA and Instrumentation Interfaces...........................................................22
7.5.3 CCTV Camera and CCTV Equipments...........................................................23
7.5.4 Control Panel/ RTU Panel/ Telecoms Cabinets...............................................23
7.6 SAFETY PRECOMMISSIONING...........................................................................23
7.6.1 Portable Fire Fighting Equipment....................................................................23
7.6.2 Safety Signs....................................................................................................23
APPENDICES
Appendix A – Pre-Commissioning Reference Document List...........................................24
Appendix B – CONTRACTOR’S Pre-commissioning Team..............................................25
Appendix C – Ready for Commissioning Certificate (RFCC)............................................26
Appendix D – Mechanism Flowchart.................................................................................27
Appendix E – Electrical Pre-commissioning Forms...........................................................28
Appendix F – Instrument Pre-commissioning Forms.........................................................29
Appendix G – Mechanical & Piping Pre-commissioning Forms.........................................30
Appendix H – Telecommunications Pre-commissioning Forms........................................31
Appendix I – Safety Pre-commissioning Forms................................................................32
Document number
1 INTRODUCTION
This manual aims to outline the general requirements and guidelines for the pre-
commissioning phase of the work, as well as provide the information and support
documents required to carry out the activities to be undertaken by the CONTRACTOR
to ensure that the pipeline, facilities, and stations are pre-commissioned in accordance
to project specifications.
2 REFERENCE DOCUMENTS
This document has been based on the latest revisions of the following documents:
GS EXP 101 Pre-commissioning and Commissioning Specification
GS EXP 103 Pre-commissioning and Commissioning Technical Preparation
GS EXP 105 Pre-commissioning Execution
YE-001-20-SOC-LIS-09286 Systems and Subsystems List
YE-001-20-SOC-DRW-09287 Systems and Subsystems Definitions and Limits
YE-001-20-SOC-PRC-09284 Punchlist Management System
YE-001-20-SOC-PRC-09285 Company Witnessing/Notification Procedure
YE-001-20-MOC-LIS-09263 Pre-commissioning Check lists and Test Sheets
YE-001-20-MOC-LIS-09262 Pre-commissioning Status Index
YE-001-20-MOC-PRC-09283 Handover Completion Dossier Layout Design
YE-001-20-SOC-PRC-09303 RFC & RFSU Handover & Acceptance
YE-001-20-SOC-MAN-09302 IPCIS Administration, Maintenance & Back-Up Manual
YE-001-20-MOC-PLN-09070 HS Plan
YE-001-20-MOC-PLN-09005 Project QA/QC Plan
Note: Refer to Appendix A for the Pre-commissioning & Commissioning Document

Register
3 DEFINITIONS AND ABBREVIATIONS

CAT - Category
CCK - Conformity Check Lists
CCTV - Closed Circuit Television
CTR - CONTRACTOR (Amec Spie Hawk Int’l -JV)
CP - Cathodic Protection
CPY - COMPANY (YLNG Company Ltd)
FAT - Factory Acceptance Test
FOC - Fiber Optic Cable
HCD - Handover Completion Dossier
IPCIS - IPEDEX Commissioning Integrated Services
ITP - Inspection and Test Plan
NDT - Non-Destructive Test
PCS - Passive Cooled Shelter
PFD - Process Flow Diagram
PID - Piping Instrumentation Diagram
PL - Punchlist
PTW - Permit to Work
QC - Quality Control
QA/QC - Quality Assurance and Quality Control
RFC - Ready for Commissioning
Document number
RFCC - Ready for Commissioning Certificate

SCADA - Supervisory Control and Data Acquisition System
SOW - Scope of Work
STS - Static Test Sheet
TEG - Thermo Electric Generator
VEN - Vendor
4 SAFETY
Safety of both personnel and plant will be the priority throughout the pre-commissioning
phase. Thus, the CONTRACTOR shall only use competent and experienced personnel
to carry out the pre-commissioning in each discipline.
During the completion of construction and pre-commissioning activities the

CONTRACTOR shall be responsible for implementing the Safety Procedures and Work
Permit System applied on site.
All Health and Safety Procedures for the YLNG project must be adhered to before and
during the execution of all pre-commissioning activities.
5 RESPONSIBILITY
Key personnel responsible for the effective execution and completion of pre-
commissioning activities will include but not be limited to:
CTR Construction/ Pre-commissioning Execution Team

To avoid confusion, the Construction/ Pre-commissioning Execution Team will
consist of the Construction Discipline Engineers and Supervisors/Foreman.
o Responsible for ensuring that the pre-commissioning activities are in accordance with
the CONTRACT and project requirements and specifications.
o Ensure that installation, construction, conformity verifications, calibrations and
testings are carried out in conformance with the design and project requirements.
o Ensure that the subsystems are mechanically complete and are Ready for
Commissioning in a safe manner.
o Complete check lists and test sheets according to his relevant discipline for
completion of the Pre-commissioning Dossier
o Involvement in generating the punchlist items as required
o Coordinates with CPY Construction Authority of the approval and acceptance of the
pre-commissioning activities performed.
o Mark up the installation drawings as installed on site
The CTR Nominated Pre-commissioning Team is detailed in Appendix B. Note that

this list may change any time.
CTR Construction Authority - Site Manager

o Responsible for ensuring that the pre-commissioning activities are in accordance with
the CONTRACT and project requirements and specifications.
o Reviews the Pre-commissioning Dossier
Document number
o Involvement in generating the punchlist items as required

o Endorse and sign the RFCC for the approval of CPY Construction Authority
Design / Engineering Authority

o Provides the basis of design, vendor and engineering data.
o Reviews and update the final engineering drawings as per the marked-up drawings
or “as pre-commissioned” drawings prepared by the Construction Team.
Health & Safety Engineer

o The H&S Manager assures that all pre-commissioning activities are performed in a
safe manner and in accordance with the health safety and environmental plan.
o Responsible for tool box talks before starting of every activity.
QA / QC Engineer
o Ensure that installation, construction, conformity verifications, calibrations and
testings are carried out in conformance with the inspection and test plans and project
requirements.
o Ensures issues of test packages, certifications, calibrations of instruments and tools.
Document Controller/ Technical Clerk

o Arrange and prepares the Pre-commissioning Dossier as per project requirements
and specifications
o Ensures that all relevant check lists and test sheets are incorporated in the pre-
commissioning dossier
o Follow up with the pre-commissioning execution team and update the Status Index
6 PRE-COMMISSIONING METHODOLOGY
6.1 SCOPE OF WORK AND ACTIVITIES

Pre-commissioning activities shall be understood as a scope of the construction team.
It is organized by system and subsystems following an approved sequence that
optimizes the commissioning and start-up phases. Three main activities define the
pre-commissioning phase:
6.1.1 Conformity Check

The Conformity check is the visual verification of the condition of an equipment, the
quality of installation and the compliance with project drawings and specifications.
o Check List
Conformity checks shall be carried out in accordance to the OPERCOM Check
Lists (CCK) for a specific discipline. These check lists define the exact scope of
work that shall be systematically performed on every item of equipment or on
selected packages and constitute the support documents to report the checks
performed.
Document number
One check list is filled in per subsystem and per type of equipment for each
discipline.
The CONTRACTOR’s Discipline Engineer performing the checks shall initialize

each check of the list when it is satisfactory and he will do so for every item of
equipment listed on the Check List.
Any check which is not satisfactory, if not immediately and properly corrected by
the CONTRACTOR shall be included in the CTR’s punch list and CTR shall take all
necessary actions to have the item cleared. If the remedial work does not fall in the
CONTRACTOR’s SOW (such as defect on equipment free issued by COMPANY),
CTR shall report it to the COMPANY, include in the CPY’s punchlist and the
COMPANY shall be responsible in clearing the item with assistance from the CTR
as required.
The Check List will be transmitted to the CTR Construction Supervisor in charge of
the concerned discipline who will review the checks, date, and sign the appropriate
signatory boxes. Upon completion, the signature of CPY Construction Authority
should be obtained for approval of the checks carried out.
6.1.2 Static / de-energized tests

Carried out on equipment to ensure the quality of a number of critical components.
Static/ de-energized tests shall be carried out on equipments in accordance with
technical specifications and shall be reported on the appropriate OPERCOM Test
Sheets (STS). This called “cold testing” concerns all disciplines (e.g. calibration of
instruments, pressure testing of piping, and cable continuities, etc). One test sheet
is filled in for each test performed.
o Test Sheet
CONTRACTOR’s Discipline engineers should ensure that all checks have been
completed prior to carrying out any test. He shall ensure that the worksite is clean
and that all test equipment is available to properly execute the test.
If the test cannot be completed or failed to obtain satisfactory results due to any
defects, the CONTRACTOR shall treat the defect the same manner as described in
6.1.1.
After completing the Test Sheet, it shall be reviewed and signed by CTR
Construction Authority and CTR Commissioning Authority. The signature of the
CPY Construction Authority should be obtained for approval and acceptance of the
test performed.
6.1.3 Piping Test (Test Pack)

Carried out on pipe works and vessels, NDT Clearance, Cleaning and Gauging,
and pressure test (i.e. hydrotest). The test pack shall record and include for each
element the information but not limited to the following: type of piping, bolts,
flanges, quality of welding, quality of painting, and type of gasket assembly.
Document number
The Test Packs breakdown may not fully match with a hierarchical sub-system
breakdown. CTR Pre-commissioning Team shall provide Tests Pack dossiers
referenced with associated sub-system, with listing of the lines included (PID
identification) and the Test Pack dossier for approval and acceptance of the
COMPANY.
The contents of a Piping Test Pack, as a minimum shall be as follows:

o Test Pack No
o Hydrotest Schematic (Test plan) where applicable
o Isometric drawings or site sketches, where applicable
o Flange make-up tagging procedure and/or Flange Check register
o PIDs (marked-up limits of test indicating test scope)
o QA/QC reports, documentation and certifications
o Appropriate pre-commissioning forms
Piping test packages should be pre-fixed with a two letter identification such as “TP”
indicating Test Pack and should carry the number of the subsystems (e.g. 33512)
plus the number of the test section (e.g. 26A) to be tested. As an example: TP-
33512+26A.
6.2 READY FOR COMMISSIONING (RFC)

Ready for Commissioning (RFC) is the act of presenting to the Company that all pre-
commissioning activities are complete. It will be formalized by the signature of the
"Ready for Commissioning Certificate” (RFCC) by the CONTRACTOR Construction
Authority and COMPANY Construction Authority and countersigned by both
Commissioning Authorities from CTR and CPY.
RFCC (see sample form in Appendix C) facilitates the handover of the sub-system
between Construction (CONTRACTOR and/or VENDORS) and the party responsible
for Commissioning, in this case, CONTRACTOR Commissioning Authority validated
by the COMPANY Commissioning Authority. This certificate is achieved through the
cross-inspection by the CTR and CPY Commissioning Authorities of the subsystem
facilities, actual witnessing by the CTR and CPY Commissioning Authorities of at
least critical pre-commissioning activities, the establishment of the mutually agreed
punchlist (if any), and the thorough review of the pre-commissioning dossier.
The transfer for a given subsystem will take place when the subsystem has reached
the “Ready for Commissioning” (RFC) status, i.e. when:
o All pre-commissioning operations on that subsystem are complete, with the

possible exception of a reasonable/minimum number of punch list CAT “B” and
CAT “C” items and all CAT “A” PL items are closed
o No punchlist item affects the operation, safety, and/or the commissioning
activities of the subsystem
o The subsystem area is clean, free from debris, tools, and extraneous material
which would impede operation or cause an unsafe condition
Document number
o The Pre-commissioning (RFC) Dossier has been compiled, submitted for review
and approval of CONTRACTOR and COMPANY Construction and
Commissioning Authorities.
Refer to “RFC & RFSU Handover & Acceptance” document number YE-001-20-SOC-
PRC-09303.
6.3 STATUS INDEX

All information gathered from the various Engineering and Vendor equipment lists will
be recorded in the Status Index. Arranged per subsystem, discipline and type of
equipment, it will indicate for each item of equipment the corresponding pre-
commissioning tasks i.e. checks and tests by showing the reference number of the
task report document.
The completion data of each task is recorded on the status index so that it is a
working document used to follow up the work progress. It is therefore, the summary
of all the pre-commissioning scope of work recorded and monitored in IPCIS.
6.4 PRE-COMMISSIONING PUNCHLIST

Prior to offering or applying for Ready for Commissioning, the pre-commissioning
dossier shall be reviewed to ensure that work has been constructed/maintained as per
design and that the equipment/subsystem integrity is valid. All discrepancies, defects,
damaged or missing equipments, malfunctions, missing documents, and all
outstanding items of work according to the original work scope shall be detailed in the
punch list.
Any outstanding pre-commissioning punchlist shall be carried forward to the

commissioning punchlist for resolution of the appropriate party CONTRACTOR,
VENDOR, and/or COMPANY. Punchlists shall remain live and tracked until all items
are completed and signed off.
Refer to document number YE-001-20-SOC-PRC-09284, Punchlist Management

System.
6.5 SEQUENCE OF EVENTS

It is important that the sequence of events is clear to all responsible parties for the pre-
commissioning activities. Following the mechanism flowchart attached in Appendix D.
After identifying the systems, subsystems, marking up the limits of systems, allocating
the inspection and test plans/requirements, and populating the technical database, the
following sequence should be followed.
a. The CTR Pre-commissioning Execution Team should complete all the pre-
commissioning requirements for the subsystems as defined in the Status
Index.
b. The status index and IPCIS should be updated and all completion dates of the
tasks should be recorded.
Document number
c. All completed check lists and test sheets, marked-up drawings, and punchlists
raised (if any) and all required reports and documents should be compiled to
form the Pre-commissioning Dossier (RFC Dossier).
d. The CTR Construction Authority then reviews the Pre-commissioning dossier,
issues and signs the RFC validating the completion of the work.
e. The CTR Commissioning Authority reviews the dossier for acceptability and
when satisfied, countersigns the RFCC.
f. RFCC should then be issued to CPY Construction Authority for approval and
acceptance and countersigned by the CPY Commissioning Authority.
6.6 PRE-COMMISSIONING DOSSIER

All documentation pertaining to Pre-Commissioning shall be complied within a specific
dossier, arranged by System/Subsystem and by discipline and shall contain the
following information as a minimum:
o Ready for Commissioning Certificate (RFCC)
o Sub-system description with marked-up system limits
o All relevant punchlists
o Check lists and test sheets
o Pre-commissioning Status Index
o Vendor Documents / Reports/ FAT
o As Built Drawings (updated marked-up drawings as per installed on site)
o Engineering Queries and variations
o List of modifications (if any)
Each subsystem shall have the following: an individual RFCC, Subsystem Punchlist (if
any), and shall be compiled in a separate pre-commissioning dossier. The pre-
commissioning dossier, upon completion will form part of the Handover Completion
Dossier (HCD).
7 PRE-COMMISSIONING PROCEDURES
This section provides the basic information and procedures required to carry out pre-
commissioning activities on site in a planned, safe and efficient manner. This however
does not intend to be fully comprehensive and hence shall be used in conjunction with
the appropriate technical specifications. This covers the simplified pre-commissioning
scope of work applicable for each discipline.
7.1 EXCEPTIONS AND SPECIAL CASES

A reduced pre-commissioning scope of work will be performed by the CTR on the
packages, which will have been thoroughly tested at the manufacturer/ supplier’s
place, prior to the pre-commissioning phase on site. Unless stated otherwise in the
CONTRACT, the packages shall be pre-commissioned in accordance with the same
procedures as those applied on field equipment. Each packages tested at the
manufacturer’s should be confirmed by the Factory Acceptance Test Certificate (FAT)
attached to the FAT Report and the punch lists raised if any.
Document number
The only packages to which the reduced scope applies are specifically listed as such
in the CONTRACT. Packages to be pre-commissioned will be identified in the pre-
commissioning Status Index. The reduced scope shall be the following:
o A single package Check List shall be performed, instead of various equipment
Check lists. Mechanical Package will be recorded in the Mechanical Check List
C-ZM-01-M whereas Electrical and Instrument package will be recorded in C-
ZM-01-E and C-ZM-01-I respectively.
o The pre-commissioning Tests will be limited to:
- Electrical: insulation and continuity tests
- Instrument: calibration and cables continuity tests between the item of
equipment and the marshalling cabinet in the Technical or Control Room,
telecom/SCADA shelter of all equipment related to safety: alarm and
shutdown devices, safety valves, etc.
- Mechanical/Piping: alignment of all equipment and flushing of all piping
reinstated on site by the CONTRACTOR.
o Building, Shelters and Structures (includes Fences, Roof beams, Security Doors
foundations, and Gates)
- All checks and inspections related to structural works (steel, roofs, gates,
etc) shall be recorded in the mechanical pre-commissioning check list C-
QX-01. The CTR Construction Authority should ensure that inspections
have been completed prior to submitting for approval to the CTR
Commissioning Authority. The CTR Construction Authority should check
the installation against design specifications, requirements and approved
drawings. The acceptance of the forms will form part of the Pre-
commissioning Dossier.
7.2 ELECTRICAL PRE-COMMISSIONING

This will cover the inspection and testing of electrical equipment prior to installation,
inspection and testing of installed equipment and circuits before and after energisation.
The related electrical pre-commissioning forms can be found in Appendix E.
The inspection and test procedures in this section are confined and may not
necessarily cover all electrical equipment and circuits included in the design.
Equipments and/or subsystems that have a stand-alone pre-commissioning procedure
should be referred to their specific procedure.
Vendor’s assistance during pre-commissioning of vendor supplied electrical

equipments (i.e. TEGs, CP, and PCS) will be requested by the CTR. The steps
required prior to the initial energising of an electrical system so that it becomes
connected to an existing electrical network, shall be jointly agreed by the authorised
electrical persons responsible for each electrical network.
Pre-commissioning activities for electrical equipment and systems shown in the single
line diagrams shall be carried out with good engineering practice and in accordance
with contractual requirements, project specifications, one line diagrams, cable lists,
equipment list, and vendor drawings and specifications.
Document number
Pre-commissioning activities associated with electrical items in a process shall include

and cover all equipment together with the control circuit of individual motor up to and
including, operation of contactors or circuit breakers that are part of the relevant
electrical system. Resetting of current and power transformers, instruments and
primary injection relays is not required, provided that vendor test certificates are
available and no visual damage is found during inspection.
7.2.1 Cables (Multicores/ multipairs, Field, LV Cables)

All field cables and multicore cables relevant to power outlets, fire and gas
detection, telephone, control, and telecommunications shall be recorded in the
electrical pre-commissioning check list C-PX-10 and the associated Test Sheet T-
PX-10.
For the case of LV cables, electrical pre-commissioning checklist C-PX-09 and test
sheet T-PX-09 will be used to record all the data for the insulation resistance and
continuity tests.
For Multicore cables two cases must be considered:

o Case 1: Multicore cables allocated to a system or sub-system.
They will be part of the corresponding system or sub-system. This is often the
case for packages. It is also the case for some systems, for example gas
detection system. In this case Multicore (Multipairs) cables shall be treated in
the same way as field cables.
o Case 2: Multicore cables with cores allocated to two or more systems.
These cables will be gathered in a Multicore cable system (including the
Junction boxes). The Status Index of this system will clearly indicate the
system corresponding to the different cores (pairs).
The following inspection and test procedures are applicable to all cable sizes
and types (including multicore cables). All cables shall be tested in
accordance with the specified Standards and Codes of Practice.
Inspection Post Installation

a. Compare the cable size, type, routing and numbering with the cable schedule
and relevant electrical drawings, paying particular attention to any special
requirements. Ensure that the core identification agrees with the connection
diagrams and phase sequence.
b. Ensure that the gland certificates meet the area classification and
specification requirements and inspect the cable glands for tightness and
ensure that the correct type of gland has been used.
c. Where necessary, check that the glanding is in accordance with the
manufacturer’s instructions and that earth tails have been terminated at a
suitable earthing terminal.
d. Where conductors have been terminated using crimped connections, ensure
that the correct size and type of crimped connection has been used.
e. Inspect the earth connections.
Insulation Resistance
The CTR Electrical Engineer shall carry out and record all data for the insulation
resistance and continuity tests with the cable ends glanded and prepared but not
Document number
connected. On completion of the tests, the cable will be connected and all core
marking shall be checked for correctness.
The insulation resistance of all buried cables shall be measured before and after
backfilling. Buried cables shall also be tested for security of overheat by
measurement of the armouring insulation resistance after consolidation of the back
filling.
Continuity tests shall be carried out for each core and each core number, test
number, and test results shall be reported in the Test Sheet. Continuity tests shall
cover the whole cable circuit as indicated on the trouble-shooting diagrams, from
the initial point (generally control room marshalling cabinets) to the final element on
the field irrespective of the multicore subsystem limits.
7.2.2 Junction/ Marshalling Box

Junction boxes shall be checked following the same rule as defined for multicore
cables. Junction Boxes should be inspected after final assembly, meaning when all
checks and tests of the cables connected to them are completed.

a. The CTR Electrical Engineer should ensure that junction box location is
correct in the drawing and are adequately supported and identified with tag
numbers.
b. Check that all earthing (internal and external) are correct.
c. Ensure that the glands and accessories are correctly fitted and that the box is
properly sealed.
All checks should be recorded in the Electrical Pre-commissioning Check List C-

PX-31. No testing of Junction Boxes is required, with the exception that an earth
continuity test is carried out.
7.2.3 Earthing and Bonding

All fields in the pre-commissioning check list C-PX-26 shall be completed and all
tests shown on the Test Sheet T-PX-26 shall be carried out by the CONTRACTOR.
Earthing and bonding, for the electrical systems and installations should be
inspected and tested in the following manner:

a. Compare and check the earth connection type and size with the electrical
schedule drawings, earthing layout drawings and specifications.
b. Where conductors have been terminated using crimped connections, ensure
that the correct size and type of crimped connection has been used.
c. Check and inspect that all earth connections are tight and greased (where
required).
d. Ensure that no screwed compression type fittings have been installed in
earthing conductors
Testing
Document number
a. Each separate earthing point, which may consist of one or more electrodes,
shall be tested with a standard earth test whenever practical.
b. The resistance as measured from any part of the system to the main earth
point should not normally exceed the values noted below and tests shall be
carried out to confirm this and should be witnessed by COMPANY:
i. Electrical Earthing - 1 ohm.
ii. Static Bonding - 10 ohms.
iii. Earth Loop - Onsite
c. The minimum number of bolted connections has been included but adequate
provision has been made for testing purposes
d. All bolted connections have been fitted with anti-vibration locking devices, and
that the materials used are such as to minimise risk of corrosion
e. The resistance before and after connection of each earth electrode shall be
measured and also the resistance to earth of all points including transformer
neutrals, centre taps, earth bars etc.
f. The impedance of the earth loop for all classes of earth (power, instrument,
etc) shall be measured and recorded and verified by COMPANY.
7.2.4 Batteries
All battery checks shall be recorded in the C-PX-17 pre-commissioning form and all
tests results shall be recorded in T-PX-17. The pre-commissioning tests to be
performed on batteries are designed to allow the charge and discharge tests and
also as maintenance record.

a. The CTR Electrical Engineer should ensure that the battery rack or cabinet
shall be correctly assembled, installed and securely fastened down.
b. Ensure that manufacturer’s recommendation and special installation and
testing procedure will be followed.
c. The nameplate rating of the equipment, number, type and rating of the
batteries supplied should be noted and compared with the ratings stated on
the approved drawings for the equipment.
d. Ensure that equipment certificates meet the specification requirements.
e. Check and confirm that batteries are identified and each cell is numbered.
f. Ensure that all installed cables have been tested and check and confirm cell
type and battery make up for correct voltage output is as per project/vendor
data.
g. Inspect for cracks, damages, tightness, and cleanliness of connections and
terminals
h. Where applicable, inspect the battery electrolyte level in all cells after filling
Testing
Only the following will be done under this test in preparation for commissioning and
initial charging.
a. When all inspection and tests and the specific gravity of the electrolyte have
been checked, the batteries may be given their initial charge. Specific gravity
of the electrolyte shall be checked before charging. COMPANY to witness.
b. Each cell voltage shall be recorded.
c. Each battery voltage shall be recorded.
d. Battery bank voltage shall be recorded.
Document number
e. Check the operation of the battery earth fault alarm (where fitted), and
measure the earth current flowing for a zero impedance earth fault. Ensure
that the measured value is below the drop off current level for all shutdown
relays.
f. Check the operation of all alarms and trips including the main supply and
charge failure alarms and the battery charger rectifier failure alarms and trips
(where fitted) and compare against manufacturer’s data.
g. Carry out the battery discharge test following the Vendor procedures and
instructions.
7.2.5 Distribution Boards

The CONTRACTOR shall carry out the insulation resistance tests on all distribution
board, main circuits and also any control wiring. The circuit breakers are to be
checked for mechanical operation and also checked against design documents to
ensure correct rating for circuit and record on the test sheet T-PX-15 and to the
corresponding check sheet C-PX-15.

a. Check that the equipment is de-energised and safe prior to commencing any
work.
b. Check equipment is correctly preserved and that no mechanical damage has
occurred.
c. Check and confirm that the equipment is securely fixed and installed in
accordance with the layout drawings.
d. Check and confirm that the equipment tag is correct, properly attached and
clearly visible.
e. Verify that earthing of the distribution and bonding of cover plates and doors
is as per project installation details and specifications.
f. Check that all covers, doors, gland plates are in order and that all bolts are
present.
g. Check that all multicore cables and electrical cables against project single line
diagrams and ensure that the rating is correct for the application.
h. Check internal wiring for neatness and correct identification.
i. On completion of the above, attach CHECKED label clearly signed and dated.
Testing
a. Enter all nameplate details on to the test sheet.
b. Review the equipment with respect to the datasheet and verify compliance.
c. All outgoing circuit breakers are to be checked for mechanical operation and
also checked against design documents to ensure correct rating for the circuit
and results to be recorded in the test sheet.
d. Carry out the insulation resistance tests on all distribution board, main circuits
and also any control wiring.
e. Carry out an earth return path impedance test and record the value on the
Test Sheet.
7.2.6 Cable Trays

The CTR should ensure that the installations of cable trays are complete with all
fittings to form a continuous cable route. Cable trays shall be bolted down to the
Document number
supports and there should be no welding permitted. All checks performed shall be
recorded in the pre-commissioning check lists C-PX-30.
7.2.7 Thermo Electric Generators (TEGs)

Electrical installation of the TEGs shall be complete in all aspects as defined in the
specifications, drawings and manufacturer’s instruction. Pre-commissioning of
TEGs shall be supported by FAT reports and certificates and shall be referred to in
the vendor document number YE-001-20-617-PRC-11477. The CCK to be utilized
for recording the visual checks for the TEGs shall be C-ZM-01-E.
7.2.8 Cathodic Protection System

Pre-commissioning of CP System can be referred to vendor document number YE-
001-20-619-PRC-11506. All checks performed for cathodic protection system shall
be recorded in the check list C-PX-33 and all tests performed shall be recorded in
the test sheet T-PX-33.
7.3 INSTRUMENT PRE-COMMISSIONING

This details the requirements for the installation and testing of standard process
control and instrumentation equipments.
All equipments/devices should be accompanied by the appropriate certification, FAT,

or referenced as being reviewed and accepted. To ensure early detection of damage,
all equipment inherently suitable shall be calibrated and should be accompanied by a
calibration certificate.
As a general rule, checks related to various types of equipment shall not be reported
on the same Check List. The check list C-JX-04 shall be used for different types of
instruments indicated in Appendix F. A general test sheet form T-JX-00 will be used to
report any checks and inspections and required tests on instrumentation equipment
except for equipments that have a specific test sheet.
7.3.1 Flow Element (Orifice Plate)

Flow elements like orifice plates should not be installed until the line flushing has
been completed. Orifice measurements according to the Test Sheet shall be
performed prior to orifice plate installation and shall be inspected to ensure that the
data and material follows the project specification. All checks have to be recorded in
the instrument pre-commissioning check list C-JX-15 and tests to be recorded in T-
JX-07 where a test label shall be attached after the measurements have been
performed.
Preliminary review of the installation site for the orifice plate should be carried out at
a suitable point in construction to ensure that requirements identified on the PID,
hookup diagrams and specification (particularly with reference to straight lengths of
pipe / turbulent flow and vibration) have been satisfied. Orifice plates should be
examined for flatness and to ensure that they are undamaged and installed in good
position.
Document number
7.3.2 Control Valves and Accessories (Modulating)

Control Valves shall be stroke checked by the CONTRACTOR throughout the
range prior to installation. The CTR should complete all checks performed in C-JX-
24 check list and all tests should be recorded in the T-JX-01 test sheet. The
CONTRACTOR shall complete the results on the test sheet and note any
adjustments made in the remarks section.
Prior to operation the valve seat shall be checked for cleanliness. All auxiliary
equipment mounted with the valve shall be calibrated/function checked and all test
results recorded on the test sheet.
Control valves with other types of actuator, e.g. piston operators, air cylinder
operators, electro/hydraulic or electric motor operators should be tested for stroking
and failure action in accordance with the manufacturer's instructions. All valve
accessories shall be checked for correct function, this shall include limit switches,
solenoid valves and any associated test over-ride facilities.
7.3.3 Actuated Valves and Accessories (ESDV, MOVs, GHOVs)

Similar requirements for control valves apply on this type of valves. All checks shall
be recorded in the Check list C-JX-23 and all tests results shall be recorded in the
Test Sheet T-JX-02.
The instrumentation engineer should inspect the condition of the valve and
accessories, including cleanliness of the seat, and the correct position and
orientation, review the valve and accessories with respect to the datasheet and
valve dataplates and check / complete the instrument datasheet number in the test
sheet. In addition whenever limit switches are installed on actuated valves they
shall be adjusted as per the VENDOR recommendations.
o Emergency Shutdown Valve (Pneumatic)

For low torque ball or plug valves pneumatic actuators shall be used, air to
close spring to open. These shall be stroke checked complete with capacity
pots, prior to installation and all relevant sections of the Test Sheet completed.
VENDOR package valves shall be tested, in situ by the CONTRACTOR.
7.3.4 Relief Valve

The initial requirements of this Test Sheet are generally the same for the control
(modulating) valve. All checks related to relief valve shall be noted in C-JX-21 and
all tests shall be recorded in T-JX-03. VENDOR package valves shall be removed
by the CONTRACTOR and tested in the same manner. All relief valves shall be re-
installed by the CONTRACTOR prior to Commissioning.
All relief valves shall be tested on air or nitrogen and adjusted to commence to
open at the cold test pressure. This cold test pressure shall include the corrections
for service conditions or back pressure or temperature, or both.
The seat leakage test shall be carried out in accordance with ANSI B 147.1 and API
527 with an applied pressure under the disc of 90% of the cold test pressure and
Document number
will be conducted using the test bench equipment approved by COMPANY. The
acceptance criteria shall be as follows:
- Resilient seat seals - zero leakage
- Metal Seats - less than 5 bubbles per minute.
Should any valve not conform to the test requirements listed on the data sheet, it
shall be brought to the attention of the COMPANY prior to remedial work being
carried out on the valve. For safety valves installed on hydraulic packages/systems,
valves shall be removed for testing only when requested by the certifying authority
to avoid contamination of hydraulic circuits. The COMPANY shall make available to
the certifying authority, original factory test certificates for all valves falling into this
category.
7.3.5 Instrument Packages

Pre-commissioning checks for instrument packages shall be recorded in the check
list C-ZM-01-I except when specific pre-commissioning forms exist. The
requirements of the VENDOR calibration manual should be adhered to enabling the
Vendor to complete the Test Sheet. Testing of devices shall be carried out prior to
installation with the exception of VENDOR package equipment which shall be
tested in situ. All calibration certificates, FAT reports and procedures, and vendor
drawings and instructions shall be reviewed and checked by the CTR
Instrumentation Engineer prior to proceeding with installations and testings.
7.3.6 Instrument (Analog Input/Output)

All tests for instrument analog output such as temperature transmitter, pressure
transmitter, pressure gauges, and local temperature indicators shall be recorded in
the pre-commissioning test sheet T-JX-04. Calibration and testing certificates will
be provided by the vendor. These instruments may be re-calibrated on site as
required or requested by the COMPANY.
7.3.7 Instrument (Switched/ Digital Output)

Switched Output relates to, but not limited to, pressure switches, trip amplifiers,
alarm annunciators, limit switches, pig signalers, etc. Test sheet T-JX-05 should be
completed for recoding the records for instrument switched output devices.
7.3.8 Instrument Tube/Pipe (Pneumatic, Impulse)

The CONTRACTOR should ensure all air supply/transmission/process/hydraulic
lines are correctly hooked up, as per relevant drawing. The Instrument scope of
work for pressure testing includes all tubes and pipes that do not carry a line
number as dictated by the piping line list and is identified by its own tag. All
instrument pipework shall be flushed. Prior to flushing main process lines, control
valves, softseated valves, orifice plates, etc., should be removed from the process
lines and suitable spool pieces inserted. Pre-commissioning test for this item is
limited to the Test Sheet T-JX-06.
7.3.9 Fire, Smoke and Gas Detection

When performing the pre-commissioning of the fire and gas detections, the CTR
Discipline Engineer should make reference to manufacturer’s instruction and
Document number
manual YE-001-20-6230-MAN-12340. Visual check should be verified against YE-

001-20-MOC-DRW-06406 and record the results in check list C-JX-42.
7.4 MECHANICAL AND PIPING PRE-COMMISSIONING

This section covers the pre-commissioning checks and tests related to:
o Piping cleaning
o Piping and related fitting/valves checks
o Painting checks
o Steel structures checks
o Mechanical Equipment
7.4.1 Mechanical Equipment Packages

Pre-commissioning activities for mechanical equipment and systems shall be based
on PIDs, vendor drawings and instructions and they will cover any equipment
shown in the project PIDs.
Before installation, materials must undergo a ‘’visual examination’’ to determine any

damage or breakage to prevent the installation of materials that will require
replacement at a later stage. This check will be generally carried out at the
warehouse, but for some materials which must be transported to the place of
installation in their packing, it can be carried out on site. Inspection must be carried
out during construction or when systems or a constituent part of them are
mechanically completed to ensure that the equipment and individual components
are installed in accordance with design requirements, Vendor’s instructions,
technical and accident prevention codes, and that there is no obvious damage or
breakage.
In the case of areas with potentially explosive atmospheres or fire, checks must be
carried out to components, and should be installed in compliance with appropriate
codes. All checks shall be reported in the pre-commissioning check list C-ZM-01-M
and all tests shall be recorded in the general test sheet T-MX-00.
7.4.2 KPU Gas Metering Package

Pre-commissioning of the metering package shall be supported by vendor
documents, FAT Procedures, FAT Reports and Certificates, and Manuals. Refer to
vendor document number YE-001-20-621-PRC-12221 for installation and operation
manual.
7.4.3 Vent Stack Package

The CTR Construction Engineer should ensure that the installation of the vent stack
package is in accordance to the vendor drawings and instructions. The checks
performed for the vent stack shall be recorded in the pre-commissioning check list
C-VX-06.
Document number
7.4.4 Pig Launchers, Pig Receivers

Vendor supplied vessels will normally have been pressure tested at the vendor
place as part of the acceptance tests and shall only require re-test on site. The
testing of pig launchers and pig receivers will be carried out in accordance with the
technical requirements of the project specifications. Each vessel installed shall be
ensured that the installation conforms to drawings and specifications. Each
installation and checks shall be approved by the acceptance of the pre-
commissioning check C-CX-02.
7.4.5 NDT Clearance

NDT Clearance Test Sheet T-MX-07 will be used to record the NDT Inspection,
results and completion. One Test Sheet is to be completed for each test packs
indicating the test number, line numbers, weld numbers, PID numbers, a
verification of visual inspection, and NDT and post weld heat treatment completion.
This form must be completed prior to proceeding with pipe cleaning.
7.4.6 Painting, Coating & Insulation for Piping

Visual checks shall be carried out by the CTR Piping Engineer on structural
surfaces or piping works that requires painting, coating or insulation. He shall
ensure that the activity performed is in compliance with Project procedures, ITPs
and specifications. All checks shall be recorded in the Check list C-XX-01 for
insulation and C-XX-02 for painting.
7.4.7 Pipework (Cleaning & Gauging, Pressure Test, Dewatering, Drying)
PRE-TEST INSPECTION GUIDELINES

Prior to starting flushing or pressure test activities, the following should be checked:
o Weld inspection and NDT should be complete and recorded
o Pipework complies with the PFDs, PIDs and piping specifications
o Flange alignment, bolts and gaskets installation at all mechanical joints are to
the correct torque settings.
o All vents and drains are installed
o Correct codes/tagging of valves and instruments
CLEANING & GAUGING

Prior to pressure testing the lines shall be cleaned in accordance to the Cleaning
and Gauging Procedure YE-001-20-SOC-PRC-09529.
Each completed cleaning tests shall be recorded in the Cleaning and Gauging Test
Sheet T-MX-04 and the Cleaning Index Test Sheet Form T-MX-23 shall summarize
all the cleaning tests performed. A copy of the cleaning and gauging pre-
commissioning form with complete information filled up by the CTR Piping Test
Engineer should be included in the piping test pack when submitted for review prior
to hydrotstatic testing.
PRESSURE TEST/ HYDROSTATIC TESTING
Document number
After cleaning and gauging is satisfactorily completed, pressure testing may

proceed. Hydrostatic testing of the pipelines must be in conformance with YE-001-
20-MOC-PRC-09275.
The pressure tests to be performed on each test section shall be recorded in the
mechanical pre-commissioning test sheet T-MX-03 and all hydrostatic tests
performed shall be recorded in the Pressure Test Index form T-MX-21. This form
shall be included in the piping test pack prepared by construction team and where
the original will be filed in the pre-commissioning dossier of the subsystem.
For each test, the following documents shall be completed and shall be included in
the pre-commissioning dossier:
o Pressure test notice
o Colored Isometrics and PIDs for test plans, where
- Blue: indicate lines to be flushed
- Green: indicate items to be removed
- Red: flanges to be disconnected
- Orange: items to be isolated
- Yellow: temporary installation (supports, spools, etc)
o Inspection clearance certificate (indicating all inspection checks and test
sheets have been carried out on the piping to be tested and that they are
satisfactory)
o Acceptance certificate for calibration of instruments
o Test acceptance certificate
o Original recorder chart
o Pre-commissioning check lists and test sheets.
o Test Logs
After satisfactory completion of the hydrostatic testing, the test sheet shall be
signed by the CTR’s Construction Authority and by the CPY Construction Authority
for the acceptance of the test.
SWABBING, DEWATERING, DRYING

CTR Construction Authority shall monitor the gradual release of pressure and drain
down. All drained lines should be dried by purging with dry air. Swabbing and pre-
air drying shall be in accordance to YE-001-20-SOC-PRC-09603 and final air drying
should comply with the procedure document number YE-001-20-SOC-PRC-09530.
The results of swabbing and drying test shall be recorded in the test sheet T-MX-
27. The test sheet index T-MX-28 should record all the swabbing/drying tests
performed.
Upon completion, the test sheet shall form part of the piping test pack acceptance
documentation and on completion the original will be issued by the CONTRACTOR
and filed in the pre-commissioning dossier of the subsystem.
7.4.8 Pressure Testing of Valves

The testing of valves shall be made in accordance with the Technical Specification
for valves. Satisfactory completion of the pressure testing for valves should be
recorded in Valve Pressure Test sheet T-MX-06. However, as the method of test
Document number
will vary for valve type, size and service, the COMPANY Engineer will inform the
CONTRACTOR of his requirements for the test. The CONTRACTOR must at all
times, have all relevant documentation available for review by the COMPANY
Engineer.
7.4.9 Bolt Tensioning and Torqueing

All bolt tensioning and torqueing will be recorded in the Test Sheet T-MX-26 which
shall be applicable to a whole subsystem. The CONTRACTOR shall ensure
installation documents and results are available at pre-commissioning stage.
Tension and torque values should be recorded and flanges identification shall be
marked-up in the isometric drawings and actual activity shall be witnessed by CPY
representative as per the pre-commissioning witnessing matrix.
7.5 TELECOMMUNICATIONS PRE-COMMISSIONING

The pre-commissioning of telecommunications equipment shall be in full compliance
with the project specification requirements, manufacturer/vendor’s specifications and
designs, and relevant drawings.
Appendix G details the check lists for telecommunications equipments.
7.5.1 Fibre Optic Cable

Pre-commissioning Procedure for FOC should be referred to vendor document
number YE-001-20-636-OPP-13732. All Fiber Optic Cable checks shall be
recorded in the Check Sheet C-PX-10 and all Test results shall be recorded in the
Test Sheet T-PX-10.
7.5.2 SCADA and Instrumentation Interfaces

The pre-commissioning of SCADA shall be supported by vendor documents and
drawings, FAT Procedure, FAT Certificates and Reports. The technical support for
installation and testing supervision will be provided by the vendor. The pre-
commissioning scope and procedures for SCADA should be referred to YE-001-20-
622-OPP-12471 and YE-001-20-622-MAN-12491. All SCADA hardwired cable
checks shall be recorded in the Check List C-PX-10 and all tests shall be recorded
in the Test Sheet T-PX-10.
7.5.3 CCTV Camera and CCTV Equipments

Inspections and checks for CCTV Cameras should be recorded in the check list
form C-IX-18 and C-IX-19. The CCTV Pre-commissioning procedure vendor
document YE-001-20-643-OPP-14459 should be referred to.
7.5.4 Control Panel/ RTU Panel/ Telecoms Cabinets

The CTR Telecoms Engineer should ensure that the panels/ cabinets and its
certificates conform to the specified design drawings, documentations and
specification requirements. CTR should ensure that internal hardware is securely
fixed and adequate access is available to all panel equipment and ensure that the
panel is not damaged and all connection hardware and cables are completed. The
Document number
pre-commissioning of the control panels/ RTU/ Telecom cabinets shall be in

accordance to all vendor drawings and instructions and all checks have to be
recorded in the checklist C-IX-08.
7.6 SAFETY PRECOMMISSIONING

All Safety Items are to be checked during pre-commissioning phase.
7.6.1 Portable Fire Fighting Equipment

Portable fire fighting equipments/package should be checked against project
specifications if properly installed/mounted in the agreed location, are of the correct
type and size, and if properly tagged. Checks of fire portable fire fighting
equipments should be recorded in the pre-commissioning check list C-YX-08.
7.6.2 Safety Signs

All safety signs should be checked for correct location, type, installation, and
visibility. The CTR should ensure that all safety signs are properly installed as per
the location layout drawings and all checks shall be recorded in the mechanical pre-
commissioning check list C-QX-03.
Appendix A – Pre-Commissioning Reference Document List
DOCUMENT NUMBER DOCUMENT TITLE
YE-001-20-MOC-MAN-09261 Pre-commissioning Manual
YE-001-20-MOC-LIS-09262 Pre-commissioning Status Index
YE-001-20-MOC-LIS-09263 Pre-commissioning Check lists and Test Sheets
YE-001-20-SOC-PRC-09529 Cleaning and Gauging Procedure
YE-001-20-SOC-PRC-09275 Hydrotest Plan
YE-001-20-SOC-PRC-09530 Final Air Drying Procedure
YE-001-20-SOC-PRC-09603 Final Swabbing and Pre-Air Drying Procedure
YE-001-20-617-PRC-11477 Factory Acceptance Test (FAT) Plan for Testing at CTR Site (TEGs)
YE-001-20-619-PRC-11506 Cathodic Protection - Method Statement
YE-001-20-625-MAN-13137 Telecommunication Network- Installation and Operation Manual
Document number
YE-001-20-636-OPP-13732 Telecommunication FO Cable Pre-Commissioning Procedure
YE-001-20-643-OPP-14459 CCTV – Pre-Commissioning Procedure
YE-001-20-643-IRF-14460 CCTV – Pre-Commissioning Report
YE-001-20-622-OPP-12470 SCADA System – Preliminary System Test Procedure
YE-001-20-622-OPP-12471 SCADA / Telecom Cabinets – FAT Procedure
YE-001-20-622-OPP-12491 SCADA Installation and Operation Manual
YE-001-20-621-PRC-12221 Metering Package Installation, Start-Up, and Commissioning Manuals
YE-001-20-MOC-LIS-09286 Systems and Subsystems List
YE-001-20-MOC-DRW-09287 Systems and Subsystems Limits Definition
YE-001-20-MOC-PRC-09283 Handover Completion Dossier Layout Design
YE-001-20-MOC-PRC-09284 Punchlist Management System
YE-001-20-MOC-PRC-09285 Pre-commissioning Witnessing Matrix
YE-001-20-MOC-PRC-09041 Waiver Request Procedure
YE-001-20-MOC-PRC-09053 Technical Queries
YE-001-20-MOC-PRC-09222 Procedure for Vendor Inspection
YE-001-20-MOC-PRC-09064 Inspection, Test & Measuring Equipment
YE-001-20-SOC-PRC-09567 As Built Procedure
YE-001-20-MOC-LIS-09234 List of Approved Subcontractors and Vendors
Document number
Appendix B – CONTRACTOR’S Pre-commissioning Team
This document is the property of Yemen LNG Company. It must not be stored, reproduced or disclosed to others without written authorisation from the Company.
Document number
Appendix C – Ready for Commissioning Certificate (RFCC)
Document number
Appendix D – Mechanism Flowchart
Document number
Appendix E – Electrical Pre-commissioning Forms
Discipline: ELECTRICAL
Form No. Description/ Designation

C-PX-02 Transformer
C-PX-09 LV Cables
C-PX-10 Multicore/Field cables (instrumentation - F&G - telecoms.)
C-PX-15 Distribution Board
C-PX-16 Charger / Inverter
C-PX-17 Batteries
C-PX-18 Lighting
C-PX-19 Socket Outlets
C-PX-26 Earthing System
C-PX-30 Cable Racking
C-PX-31 Junction / Marshalling Box
C-PX-32 Control panel / Console
C-PX-33 Cathodic Protection
C-ZM-01-E Electrical Package Equipment
C-ZM-01-E Thermo Electric Generators
T-PX-00 General Purpose Test Sheet
T-PX-09 LV Cables
T-PX-10 Multicore/Field cables (instrumentation - F&G - telecoms.)
T-PX-15 Distribution Board
T-PX-16 Charger / Inverter
T-PX-17 Batteries
T-PX-18 Lighting Circuit
T-PX-19 Socket Outlets
T-PX-26 Earthing System
T-PX-33 Cathodic Protection
T-PX-34 Thermo Electric Generators
Appendix F – Instrument Pre-commissioning Forms

Discipline: INSTRUMENTATION
Document number

C-JX-04 General Purpose Check List
C-JX-04 Local Pressure Indicator
C-JX-04 Pressure switch
C-JX-04 Pressure transmitter
C-JX-04 Temperature element (T/C or RTD)
C-JX-04 Local Temperature Indicator
C-JX-04 Temperature Transmitter
C-JX-04 Flow Element
C-JX-04 Pitot element
C-JX-04 Annubar
C-JX-04 Solenoid valve
C-JX-04 Limit Switch
C-JX-04 Density transmitter
C-JX-04 Signal selector
C-JX-04 Actuated Valve Control Station
C-JX-04 Hand Switch
C-JX-04 Thermowell
C-JX-04 Analyser
C-JX-24 Control Valve
C-JX-23 Actuated (ESD, MOV, GHOVs, On-Off Valve
C-JX-23 Motor Operated Valve
C-JX-15 Orifice Plate
C-JX-21 Relief Valve
C-JX-42 Gas - Heat - UV/IR - Smoke detectors
C-JX-47 Panel (Local)
C-ZM-01-I Vendor Instrument Package
T-JX-00 General Purpose Test Sheet
T-JX-04 Instrument (Analog Output/Input)
T-JX-05 Instrument (Switched/Digital Output)
T-JX-06 Instrument Tube/ Pipe (Pneumatic, Impulse)
T-JX-01 Control Valve
T-JX-02 Actuated (ESD, MOV, GHOVs)
T-JX-07 Orifice Plate
T-JX-03 Relief Valve
Appendix G – Mechanical & Piping Pre-commissioning Forms
Discipline: MECHANICAL & PIPING
Document number
Form No. Discipline Description/ Designation

C-ZM-01-M Mechanical Mechanical Package Equipment
C-QX-02 Mechanical Building and Shelters
C-QX-01 Mechanical Structural Works
C-VX-06 Mechanical Flare Tip Package
C-CX-02 Mechanical Pig Launcher / Pig Receiver
C-QX-02 Mechanical Buildings/ Shelters
Structural works (steel, roof beams, gates,
C-QX-01 Mechanical fences, doors)
C-XX-01 Piping Insulation of Piping
C-XX-02 Piping Painting
T-MX-00 Piping General Purpose Test Sheet
T-MX-07 Piping NDT Clearance
T-MX-03 Piping Pipework Pressure Test
T-MX-04 Piping Pipework Cleaning
T-MX-06 Piping Valve Pressure Test
T-MX-27 Piping Swabbing/ Drying Test
T-MX-21 Piping Piping Pressure Test Index
T-MX-23 Piping Pipework Cleaning Index
T-MX-26 Piping Bolt Tensioning / Torqueing
T-MX-28 Piping Swabbing/ Drying Test Index
Appendix H – Telecommunications Pre-commissioning Forms
Discipline: TELECOMMUNICATIONS
C-IX-31 Telecom PA/ GA Equipment
Document number
C-IX-06 Telephone Socket, Standard, Hotline Telephones

C-IX-10 Telephone
C-IX-08 Control/Equipment Room Telecom Console
C-IX-12 Computers/ Printers
C-PX-31 Junction Boxes / Marshalling Boxes
C-PX-10 Telecommunication Network Cables (FOC, Multicores, RJ45, RJ11)
C-IX-13 Equipment Rack (General)
C-IX-18 CCTV Central Equipment
C-IX-19 CCTV Cameras, Control Unit and Monitors
C-IX-29 Computer Local Area Network
T-PX-10 Telecommunication Network Cables (FOC, Multicores, RJ45, RJ11)
Appendix I – Safety Pre-commissioning Forms
Discipline: SAFETY
C-YX-08 Portable Fire Fighting Equipment
C-QX-03 Safety Signs
Document number

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PRE-COMMISSIONING MANUAL YE-001-20-SOC-MAN-09261

Rev. Status Date Revision memo Issued by Checked by Approved by

06 IFC 10/04/08 Issued for Construction. Modifications C.Umali P.Fernandez O.Balloy

04 IFC 28/08/07 Issued for Construction. Company C.Umali P.Fernandez O.Balloy

03 IFC 13/08/07 Issued for Construction. Company C.Umali P.Fernandez O.Balloy

02 IFC 26/06/07 Issued for Construction. Company C.Umali P.Fernandez O.Balloy

01 IFC 02/05/07 Issued for Construction. Company C.Umali P.Fernandez O.Balloy

00 IFR 14/04/07 Issued for Review C.Umali P.Fernandez O.Balloy

3 DEFINITIONS AND ABBREVIATIONS...........................................................................4

7.4.6 Painting, Coating & Insulation for Piping.........................................................20

Note: Refer to Appendix A for the Pre-commissioning & Commissioning Document

3 DEFINITIONS AND ABBREVIATIONS

RFCC - Ready for Commissioning Certificate

During the completion of construction and pre-commissioning activities the

CTR Construction/ Pre-commissioning Execution Team

The CTR Nominated Pre-commissioning Team is detailed in Appendix B. Note that

CTR Construction Authority - Site Manager

o Involvement in generating the punchlist items as required

Design / Engineering Authority

Health & Safety Engineer

Document Controller/ Technical Clerk

6.1 SCOPE OF WORK AND ACTIVITIES

6.1.1 Conformity Check

The CONTRACTOR’s Discipline Engineer performing the checks shall initialize

6.1.2 Static / de-energized tests

6.1.3 Piping Test (Test Pack)

The contents of a Piping Test Pack, as a minimum shall be as follows:

6.2 READY FOR COMMISSIONING (RFC)

o All pre-commissioning operations on that subsystem are complete, with the

6.3 STATUS INDEX

6.4 PRE-COMMISSIONING PUNCHLIST

Any outstanding pre-commissioning punchlist shall be carried forward to the

Refer to document number YE-001-20-SOC-PRC-09284, Punchlist Management

6.5 SEQUENCE OF EVENTS

6.6 PRE-COMMISSIONING DOSSIER

7.1 EXCEPTIONS AND SPECIAL CASES

7.2 ELECTRICAL PRE-COMMISSIONING

Vendor’s assistance during pre-commissioning of vendor supplied electrical

Pre-commissioning activities associated with electrical items in a process shall include

7.2.1 Cables (Multicores/ multipairs, Field, LV Cables)

For Multicore cables two cases must be considered:

Inspection Post Installation

7.2.2 Junction/ Marshalling Box

Inspection Post Installation

All checks should be recorded in the Electrical Pre-commissioning Check List C-

7.2.3 Earthing and Bonding

Inspection Post Installation

Inspection Post Installation

7.2.5 Distribution Boards

Inspection Post Installation

7.2.6 Cable Trays

7.2.7 Thermo Electric Generators (TEGs)

7.2.8 Cathodic Protection System

7.3 INSTRUMENT PRE-COMMISSIONING

All equipments/devices should be accompanied by the appropriate certification, FAT,

7.3.1 Flow Element (Orifice Plate)

7.3.2 Control Valves and Accessories (Modulating)

7.3.3 Actuated Valves and Accessories (ESDV, MOVs, GHOVs)

o Emergency Shutdown Valve (Pneumatic)

7.3.4 Relief Valve

7.3.5 Instrument Packages

7.3.6 Instrument (Analog Input/Output)