< Security Level 2 > MECHANICAL COMPLETION PROCEDURE

HPCL, Visakh ISSUED : 08.09.2008 Doc. No. : 6261A100920-001

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 HDHT PROJECT

Sheet 1of 18

DEFINITION OF MECHANICAL COMPLETION

At such respective stages as are required, it will be a contractual requirement to ensure mechanical completion of the construction works. This shall be carried out in accordance with the Definition of Mechanical Completion List. This standard format list is general and covers most construction requirements, however it can only be used as a basis for compiling a job specific procedure list, therefore each item shall be individually reviewed, assessed and revised where necessary, to ensure that all the relevant contractual requirements of the specifications, drawings, procedures, manuals, applicable codes of practice and engineering standards are fulfilled by the contractor.

Tie-ins at Battery Limits. Particular attention shall be given to all tie-ins as to when they are to be performed. The user must take into account the availability of live lines in the working plant and the time scale from commencement to completion of all the tie-ins. When this has been considered, the tie-ins shall be planned and scheduled either before and/or After Mechanical Completion.

Doc. No. : 6261 A 100 920 -001 Annexure : 1

< Security Level 2 > MECHANICAL COMPLETION PROCEDURE

HPCL, Visakh ISSUED : 08.09.2008 Doc. No. : 6261A100920-001
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 HDHT PROJECT

BEFORE MECHANICAL COMPLETION

Sheet 2of 18
AFTER MECHANICAL COMPLETION

WORK ITEM (As per Applicability of Scope of Work)

REMARKS

1.0 1.1 (1)

General requirements Permits Assist the OWNER in application of all permits and certification required to be secured for initial use of the PLANT. Apply for all permits, which are to be issued in the OWNER's name and are required for the PLANT installation, use, occupancy and operation. Vendor assistance Obtain the Vendor assistance for the installation. Obtain the Vendor assistance for the PRECOMMISSIONING. Obtain the Vendor assistance for the training of OWNER Personnel. Temporary supports, bracing and inhibitors Remove all temporary supports and bracing installed in or on equipment which was used during Construction. Remove all temporary supports and bracing which was used during construction. Remove / drain all rust preventives and inhibitors, when the equipment is ready for PRE-COMMISSIONING or COMMISSIONING. Conduct any non-operating checks to ensure instrument operability, that is, remove all shipping stops, check pointer travels and verify instrument capability to measure operate and stroke in the direction and manner required by the process application Housekeeping Maintain housekeeping of the PLANT area

(2)

1.2 (1)

(2)

(3)

1.3 (1)

(2)

(3)

(4)

1.4 (1)

Doc. No. : 6261 A 100 920 -001 Annexure : 1

< Security Level 2 > MECHANICAL COMPLETION PROCEDURE

HPCL, Visakh ISSUED : 08.09.2008 Doc. No. : 6261A100920-001
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 HDHT PROJECT

BEFORE MECHANICAL COMPLETION

Sheet 3of 18
AFTER MECHANICAL COMPLETION

WORK ITEM (As per Applicability of Scope of Work)

REMARKS

at a safe level during construction. (2) Maintain housekeeping of the PLANT area at a safe level during PRECOMMISSIONING and COMMISSIONING. Remove all remaining materials from the temporary area(s) Remove all the temporary facilities Inspection Complete all the Field Inspections required before MECHANICAL COMPLETION in accordance with Field Quality Control Procedure (up to MECHANICAL COMPLETION) Submit the Field Inspection Summary to the OWNER. Complete all special Inspections, which are required by governmental agencies, or by insurance. Carryout PMI (Positive Material Identification) Test of the limit for all process Piping, Heat exchanger Height, Vessel flanges etc. Consumables, chemicals, special tools and spare parts Lubricants Submit a list of the Vendor recommended lubricants. Charge the systems with the specified lubricants for oil flushing. Initial charge of the systems with the specified lubricants. Maintain all the lubricants during PRECOMMISSIONING and COMMISSIONING. Catalysts Load or charge all catalysts. Chemicals and other media

(3)

(4) 1.5 (1)

(2) (3)

(4)

1.6

1.6.1 (a) (b) (c) (d)

O O O O

1.6.2 (a) 1.6.3

Doc. No. : 6261 A 100 920 -001 Annexure : 1

< Security Level 2 > MECHANICAL COMPLETION PROCEDURE

HPCL, Visakh ISSUED : 08.09.2008 Doc. No. : 6261A100920-001
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 HDHT PROJECT

BEFORE MECHANICAL COMPLETION

Sheet 4of 18
AFTER MECHANICAL COMPLETION

WORK ITEM (As per Applicability of Scope of Work)

REMARKS

(a)

(b) 1.6.4 (a) (b)

Load or charge all chemicals, resins, desiccants or other media required for the PLANT. Provide all Solvents for cleaning. Media beds and packing materials Load or install all Media beds such as sand, gravel, carbon, etc. Load or install all packing material for towers and vessels such as rings, balls, saddles, etc. Spare parts and special tools Hand over to OWNER all spare parts for one or two year(s) PLANT operation. Provide all special tools and equipment. packing and seals for rotating equipment Install all the packing and/or seals, where required. Inspect, clean and install all mechanical seals, packing, etc., as required during PRE-COMMISSIONING and COMMISSIONING. Flushing and chemical cleaning Perform flushing and chemical treatment or cleaning operations. Provide all circulating fluids, chemicals, equipment and all consumable materials in order to complete the chemical treatment or cleaning. Drying out Drying out the designated systems, refractory, lining, etc., in order to continue with the Construction. Dry out the remaining systems, refractory, lining, etc., upon completing construction. Purging Provide all temporary services, connections O O

O O

1.6.5 (a) (b) 1.7 (1) (2)

O O

1.8 (1) (2)

1.9 (1)

O O

(2)

1.10 (1)

Doc. No. : 6261 A 100 920 -001 Annexure : 1

< Security Level 2 > MECHANICAL COMPLETION PROCEDURE

HPCL, Visakh ISSUED : 08.09.2008 Doc. No. : 6261A100920-001
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 HDHT PROJECT

BEFORE MECHANICAL COMPLETION

Sheet 5of 18
AFTER MECHANICAL COMPLETION

WORK ITEM (As per Applicability of Scope of Work)

REMARKS

(2)

and purge fluids etc. Carry out all associated operations such as pump down special treatments, etc.. Tie-ins at battery limits Check, plan, schedule and perform tie-ins at the battery limits, as necessary and in conjunction with existing plant priorities. Performance test Plan and schedule all the performance tests with the Vendor, where required, and the OWNER.

1.11 (1)

1.12 (1)

2.0

Specific requirement All the following items reference where applicable will be subject to Field Quality Control Procedure Mechanical installations Drums and vessels Install refractory, lining and carry out cold curing where required. Open access ways in all shop fabricated items for Field Inspection and close up. Conduct, as required, Field Inspections and testing of field fabricated items. Conduct, as required, Field Inspections and testing of shop fabricated items. Open up access ways, provide and install or load any inert packing materials and media beds such as sand, gravel, stone, balls, saddles and close up. Open up access ways, provide and install or load chemicals, desiccants, catalysts and any other operating materials, where required and close up. Refractory Dry out, if required Open and close up any access ways, where required, for Operation's Inspections.

2.1 2.1.1 (a) (b) (c) (d) (e)

O O O O

(f)

O O O

(g) (h)

Doc. No. : 6261 A 100 920 -001 Annexure : 1

< Security Level 2 > MECHANICAL COMPLETION PROCEDURE

HPCL, Visakh ISSUED : 08.09.2008 Doc. No. : 6261A100920-001
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 HDHT PROJECT

BEFORE MECHANICAL COMPLETION

Sheet 6of 18
AFTER MECHANICAL COMPLETION

WORK ITEM (As per Applicability of Scope of Work)

REMARKS

2.1.2 (a)

(b)

(c)

(d) (e)

(f) (g) (h) (I)

Storage Tanks Conduct Field Inspections and testing of the field erected storage tanks, as and where required Conduct Field Inspections and testing of the shop fabricated tanks, as and where required. Open access ways and check the internal coating or lining, correct installation of the internal piping, gauging devices, etc. Conduct chemical cleaning or flushing & cleaning as required. Test tank and internals as required Dispose of test Water in accordance with OWNERs instructions Internally Inspect tanks.. Conduct the tank strapping calibration, where required. Close up, after obtaining approval from PMC and OWNER Inspection Departments. Obtain the approval and certification of the government agency to permit the operation, where applicable. Pumps Uncouple the pump from the driver unit, set and cold align pump and driver unit, in accordance with Vendor recommendations or where applicable Technical Documents Check the bearings and charge with the specified grease or lubricant, if required or where applicable. Check the pump rotation manually, ensure freedom of movement. Couple pump and driver, after the driver has been "bump" checked for the correct direction of rotation and "no load" run. Install temporary strainers in the suction piping. Check the cold alignment after all piping is connected, adjust if required. Check all vents, drains, seals, flushing bypasses, etc., for compliance with Vendor specifications and drawings.

O O O O O O O

2.1.3 (a)

(b)

O O O O O O

(c) (d)

(e) (f) (g)

Doc. No. : 6261 A 100 920 -001 Annexure : 1

< Security Level 2 > MECHANICAL COMPLETION PROCEDURE

HPCL, Visakh ISSUED : 08.09.2008 Doc. No. : 6261A100920-001
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 HDHT PROJECT

BEFORE MECHANICAL COMPLETION

Sheet 7of 18
AFTER MECHANICAL COMPLETION

WORK ITEM (As per Applicability of Scope of Work)

REMARKS

(h) (i)

(j)

(k) (l)

(m)

Flush the hydraulic, lube and seal oil systems with flushing oil. Conduct the Mechanical Test Run in accordance with the Vendor recommendations. Conduct the bearing temperature and vibration checks during the Mechanical Test Run. Remove all temporary strainers and install the permanent strainers. Run in the pumps, conduct final hot alignment checks and complete any required doweling. Clean all strainers, after pumps have been in operation for a reasonable period. Compressors ( centrifugal and reciprocating ) Uncouple the compressor from the driver unit, set and cold align compressor and driver unit in accordance with the Vendor recommendations or where applicable the Technical Documents. Check bearings and charge with the specified grease or lubricant, if required. Clean the lube, seal and hydraulic oil systems mechanically or chemically in accordance with the Vendor recommendations or where applicable the Technical Documents. Flush the hydraulic, lube and seal oil systems with flushing oil. Charge all systems with the specified operating fluids, this shall include the water jacket, flushing and lubricating systems, etc. Prime the systems as required and install such items as air, water and oil filters etc. Chemically clean reciprocating compressor suction piping. Provide and install all the temporary suction strainers. Check the cold alignment after all piping is connected, adjust if required. Check the installation for completeness and for correct connection and tie-in of all

O O

O O O O

2.1.4 (a)

(b) (c)

(d) (e)

(f) (g) (h) (i)

O O O O

Doc. No. : 6261 A 100 920 -001 Annexure : 1

< Security Level 2 > MECHANICAL COMPLETION PROCEDURE

HPCL, Visakh ISSUED : 08.09.2008 Doc. No. : 6261A100920-001
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 HDHT PROJECT

BEFORE MECHANICAL COMPLETION

Sheet 8of 18
AFTER MECHANICAL COMPLETION

WORK ITEM (As per Applicability of Scope of Work)

REMARKS

(j)

(k)

(l) (m)

(n)

(o)
(p)

auxiliary equipment. Couple the compressor and driver, after the driver has been "bump" checked for the correct direction of rotation and "no load" run. Inspect the power transmission couplings for clearance and the angular and offset alignment. Adjust if required, taking into consideration the calculated hot and dynamic movements of the equipment and shafts. Inspect sleeves and belts for alignment and tension and adjust if required. Check compressor instruments, controls, safety and alarm devices, control valves, etc., for continuity and correct setting. Blow out with a suitable media or conduct mechanical cleaning of the process side of the compressor piping system, before connecting. Conduct the Mechanical Test Run in accordance with the Vendor recommendations. Carry out the final hot alignment checks and complete any required doweling. Electrical motor drivers Uncouple the motor from the driven unit and check the motor polarity, correct connection; i.e., "Delta" or "Wye", where applicable and voltage rating. Megger check the insulation. Set and cold align the motor and driven unit in accordance with the Vendor recommendations or where applicable the Technical Documents. Check the bearings and charge with the specified grease or lubricant, where applicable. "Bump" checks the motor, for the correct direction of rotation, and conduct the "no load" test run. Couple the motor and the driven unit. Commission in accordance with the Vendor recommendations.

O O

O O

2.1.5 (a)

O O O

(b) (c)

(d)

(e)

O O O

(f) (g)

Doc. No. : 6261 A 100 920 -001 Annexure : 1

< Security Level 2 > MECHANICAL COMPLETION PROCEDURE

HPCL, Visakh ISSUED : 08.09.2008 Doc. No. : 6261A100920-001
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 HDHT PROJECT

BEFORE MECHANICAL COMPLETION

Sheet 9of 18
AFTER MECHANICAL COMPLETION

WORK ITEM (As per Applicability of Scope of Work)

REMARKS

(h)

(i)

Check the amperage, bearing temperature, vibration and starter operation during PRECOMMISSIONING and or COMMISSIONING. Carry out the final hot alignment checks and complete any required doweling.

2.1.6 (a)

Drinking Water Install drinking water piping in the plant & Commission it. Waste Disposal Inspect facilities for completeness and correctness of installation and make any non-operating checks to ensure their conformance to specifications Operate all equipment and supply all chemicals and agents to waste treatment Obtain the services of a waste treatment consultant to advise and monitor the system operation, as required by the OWNER. Filters Fully assemble, except for the internal filter elements or media bed. Clean the equipment and systems. Inspect the installation for completeness and correct connection of instruments, drivers and auxiliary equipment. Clean the equipment and systems. Conduct pressure and vacuum tests as required. Load the final media bed such as sand, rock, gravel, carbon etc., and/or install the final filter elements, in accordance with the Vendor specification. Conduct all no operational checks. Conduct the Performance Test and adjust if required. Weigh bridge Level, calibrate and set tare weights, where possible.

2.1.7 (a)

(b) (c)

O O

2.1.8 (a) (b) (c)

O O O O O

(d) (e) (f)

O O O

(g) (h)

2.1.9 (a)

Doc. No. : 6261 A 100 920 -001 Annexure : 1

< Security Level 2 > MECHANICAL COMPLETION PROCEDURE

HPCL, Visakh ISSUED : 08.09.2008 Doc. No. : 6261A100920-001
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 HDHT PROJECT

BEFORE MECHANICAL COMPLETION

Sheet 10of 18
AFTER MECHANICAL COMPLETION

WORK ITEM (As per Applicability of Scope of Work)

REMARKS

(b)

Obtain the approval and certification of the government agency for weights and measures, where applicable. Material handling equipment Fully assemble and conduct all the required nonoperating checks such as freedom of moving parts and correct direction of rotation etc. Conduct all Performance Tests, as applicable. Obtain the approval and certification of the government agency to permit operation, where applicable. Agitators and mixers Check the installation for such items as the correct direction of rotation, the condition of blades, ribbons, helixes, etc. Check the cold alignment of, couplings, gear boxes, driver and driven units. Conduct Performance Test, adjust if required.

2.1.1 0 (a)

(b) (c)

O O

2.1.1 1 (a)

O O O

(b) (c)

2.1.1 2 (a)

Fire water system Inspect the installation for completeness and correct connection of auxiliary equipment. Conduct the Performance Test in accordance with the Vendor recommendations; this shall include checking the output of the system, pipeline flushing, flow testing and all leak checks. Obtain the approval and certification of the government agency for fire and safety, where applicable. Water disposal system Inspect the installation for completeness and correct connection of auxiliary equipment.

(b)

(c)

2.1.1 3 (a)

Doc. No. : 6261 A 100 920 -001 Annexure : 1

< Security Level 2 > MECHANICAL COMPLETION PROCEDURE

HPCL, Visakh ISSUED : 08.09.2008 Doc. No. : 6261A100920-001
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 HDHT PROJECT

BEFORE MECHANICAL COMPLETION

Sheet 11of 18
AFTER MECHANICAL COMPLETION

WORK ITEM (As per Applicability of Scope of Work)

REMARKS

(b)

(c)

(d)

Load or charge the specified chemicals and agents in order to operate the waste treatment correctly. Obtain the approval and certification of the government agency for health and sanitation, where applicable COMMISSIONING the system

O O

2.1.1 4 (a)

Packaged equipment Set and cold align the unit in accordance with the Vendor recommendations or where applicable, the Technical Documents. Clean all water jacket, lube, hydraulic and seal oil systems, starting air or gas, fuel gas or oil and combustion air systems, mechanically or chemically, in accordance with the Vendor recommendations or where applicable the Technical Documents. Inspect all systems for cleanliness. Flush the hydraulic seal and the lube oil systems with flushing oil. Charge all systems, such as the hydraulic, lube oil, lubricators, water jacket, pilot, etc., with the specified operating fluids and prime the systems as necessary. Install such items as air, water and oil filters etc. Provide and install all temporary lube oil filters, oil filter cartridges, strainer elements, etc., for the main bearings, in accordance with the Vendor specification. Inspect the installation for completeness and correct connection of any tie-in and/or auxiliary equipment Check for the correct direction of rotation of the driver and driven units. Inspect the power transmission couplings for clearance and angular and offset alignment. Adjust if required, taking into consideration any calculated hot and dynamic movements of shafts and equipment. Inspect sleeves and belts for alignment and tension, adjust if required.

(b)

(c) (d) (e)

O O

(f)

(g)

O O

(h) (i)

(j)

Doc. No. : 6261 A 100 920 -001 Annexure : 1

< Security Level 2 > MECHANICAL COMPLETION PROCEDURE

HPCL, Visakh ISSUED : 08.09.2008 Doc. No. : 6261A100920-001
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 HDHT PROJECT

BEFORE MECHANICAL COMPLETION

Sheet 12of 18
AFTER MECHANICAL COMPLETION

WORK ITEM (As per Applicability of Scope of Work)

REMARKS

(k)

(l)

Check the drivers and driven unit instruments controls, all the safety and alarm devices, control valves, etc., for continuity and the correct setting. Blow out the fuel gas or oils system, starting gas or air system, with a suitable medium. Hose stations / steam lances Install services water / plant air/LP steam hoses at the hose station Install steam lance near furnace/make-up Gas Compressor, reactor feeds pumps fractionators water bottom pump and any other area, considered necessary by OWNER for safety reasons

2.1.1 5 (a) (b)

2.2 2.2.1 (a) (b)

(c)

(d) (e)

(f)

(g)

Piping systems Line check Check all lines for correct installation in accordance with the Technical Documents Check all lines for correct installation of the pipe supports, hangers and any other piping specialities. Check all valves to insure correct type and installation as indicated in the flow diagrams and piping drawings. Check all lines for correct installation of vents and drains. Insulate or paint flanges, threaded joints or field welds after the specified testing of each system has been completed. Unless instructed otherwise by OWNER All welded joints (longitudinal girth and nozzle) in underground piping that have not been shop tested shall be left exposed (free of paint, dope and wrap) until the specified testing has been completed. After testing of these joints cover the system Check pipe hangers, supports, guides, expansion joints and other pipe specialties for the removal of all shipping and erection stops and for the correctness of cold settings for the design services. Also

O O

O O

Doc. No. : 6261 A 100 920 -001 Annexure : 1

< Security Level 2 > MECHANICAL COMPLETION PROCEDURE

HPCL, Visakh ISSUED : 08.09.2008 Doc. No. : 6261A100920-001
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 HDHT PROJECT

BEFORE MECHANICAL COMPLETION

Sheet 13of 18
AFTER MECHANICAL COMPLETION

WORK ITEM (As per Applicability of Scope of Work)

REMARKS

provide the OWNER with instructions for hot settings 2.2.2 (a) Destructive and non destructive testing Prepare and submit the Test Schedule to the OWNER. O

Only if specified in the Contract, otherwise not necessary

(b) (c) (d) (e)

Conduct testing of piping in accordance with the Technical Documents. Provide OWNER with all test records. Initial service test piping as specified and in accordance with Technical Documents. Conduct any Post Weld Heat Treatment and provide OWNER with the records. Flushing and chemical cleaning Remove and reinstall any equipment and/or components, as are necessary in order to conduct the flushing or chemical cleaning. Install and remove all the temporary blinds, strainers and spools, as are necessary in order to conduct the flushing or chemical cleaning. Install and remove temporary connections, as are required, in order to conduct the flushing or final cleaning. Provide the circulating media, chemicals and all the equipment required, in order to conduct the flushing or chemical cleaning. Clean the lines of all loose materials by flushing, blowing out or chemical cleaning. Install temporary and permanent strainers, spectacle blinds and temporary blinds after flushing or chemical cleaning, in order to conduct PRE-COMMISSIONING or COMMISSIONING. Removal and reinstallation of in-line instruments and components Isolate or remove, as required, all instruments before pressure testing and reinstate upon completion. Isolate or remove, as required, components

O O O O

2.2.3 (a)

(b)

(c)

(d)

O O

(e) (f)

2.2.4 (a)

O O

(b)

Doc. No. : 6261 A 100 920 -001 Annexure : 1

< Security Level 2 > MECHANICAL COMPLETION PROCEDURE

HPCL, Visakh ISSUED : 08.09.2008 Doc. No. : 6261A100920-001
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 HDHT PROJECT

BEFORE MECHANICAL COMPLETION

Sheet 14of 18
AFTER MECHANICAL COMPLETION

WORK ITEM (As per Applicability of Scope of Work)

REMARKS

(c)

(d)

such as control valves, positive displacement meters, turbine meters, etc., before pressure testing and reinstate upon completion. Isolate or remove all in-line components before flushing and reinstate upon completion Remove all orifice plates before flushing and reinstate upon completion. pipe supports and hangers Check pipe hangers, supports, guides, and any other pipe specialities, for removal of shipping and/or erection stops. Check pipe hangers, supports, guides, and any other pipe specialities, for correctness of cold settings. Check and adjust pipe supports, hangers, and any other pipe specialities for correctness of hot setting. Check pipe supports and all hangers for vibration. Temporary strainers Provide and install all temporary strainers. Clean strainers during PRECOMMISSIONING and COMMISSIONING Car seal valves Install car seals on valves, where specified. Check and record the position of all car seal valves. Overall tightness test Conduct Overall Tightness Tests. Conduct any special testing, cleaning or pickling as required by Technical Documents. Remove all temporary blinds. Plug or cap all vents drains upon completion of testing. Electrical systems Conduct all the nonoperating tests necessary to comply with the Vendor

O O

2.2.5 (a)

(b)

(c)

O O

(d)

2.2.6 (a) (b)

O O

2.2.7 (a) (b)

O O

2.2.8 (a) (b)

O O O

(c)

2.3 (1)

Doc. No. : 6261 A 100 920 -001 Annexure : 1

< Security Level 2 > MECHANICAL COMPLETION PROCEDURE

HPCL, Visakh ISSUED : 08.09.2008 Doc. No. : 6261A100920-001
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 HDHT PROJECT

BEFORE MECHANICAL COMPLETION

Sheet 15of 18
AFTER MECHANICAL COMPLETION

WORK ITEM (As per Applicability of Scope of Work)

REMARKS

(2)

(3)

(4)

(5) (6) (7) (8) (9)

(10)

(11) (12)

(13) (14)

(15)

(16) (17)

recommendations and warranty. Conduct all the Insulation Resistance Testing on transformers, induction motors, high and low voltage circuits, in accordance with Technical Documents Conduct all the Grounding Resistance Testing to establish the continuity of connections and the value of resistance to ground, in accordance with the Technical Documents. Conduct the Dielectric Breakdown Tests on oil samples from all oil insulated transformers. Conduct all the High Voltage Testing of cable and switchgear, where applicable. Test and set switchgear and circuit breaker relays for proper coordination Obtain CEA, Govt. of India inspectors approval, where required Provide all the correct relay settings for proper coordination. Conduct trials and adjust the motor control equipment and set the switchgear relays, where applicable. Obtain the approval and certification of the government agency to permit operation, where applicable. Check phase sequence and polarity. Energise the substations upon completion of the testing, with the approval and conducted under the supervision for coordination and safety, of the OWNER. Check the installation of the emergency and instrument power supply systems. Provide and install all the fuses during the PRE-COMMISSIONING and /or COMMISSIONING. Provide and install all the lamps during the PRE-COMMISSIONING and /or COMMISSIONING. Conduct all Lighting Tests, adjust if required. Install surface cable markers for underground cables.

O O O O O O

O O O

O O

O O O

Doc. No. : 6261 A 100 920 -001 Annexure : 1

< Security Level 2 > MECHANICAL COMPLETION PROCEDURE

HPCL, Visakh ISSUED : 08.09.2008 Doc. No. : 6261A100920-001
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 HDHT PROJECT

BEFORE MECHANICAL COMPLETION

Sheet 16of 18
AFTER MECHANICAL COMPLETION

WORK ITEM (As per Applicability of Scope of Work)

REMARKS

2.4 (1) (2) (3) (4) 5) (6)

(7) (8)

(9) (10)

(11) (12) (13) (14) (15) (16) (17)

(18) (a) (b)

Instrument systems Provide OWNER with a list of the correct settings for safety relief valves. Conduct the testing of safety relief valves and seal. Install all safety devices Lubricate control valves. Clean all gauge glasses and check illuminators. Install and connect all system components and verify their compliance with the specifications and design criteria for function and range. Leak Test all pressure pipe. Check thermocouples for correct termination, position of elements in wells, polarity and the continuity to receiving instruments. Check the bore of orifice plates and install upon completion of the flushing operations. Clean the transmission and control tubing by blowing out with clean, dry air, prior to the instrument component connection. Clean the air supply headers by blowing out with clean, dry air. Leak test all pneumatic pipe and tube. Check the continuity and resistance of the electrical circuits. Remove all shipping stops in or on instrument components. Test all alarm circuits and safety trip-outs. Change the instrument system with mercury and sealing liquid, where required. Calibrate the instruments, in accordance with the Technical Documents and within the suppliers guaranteed accuracy, with standard test equipment and attach the calibration tag, sticker, label, etc., to each device. Conduct nonoperating checks as follows:Loop check of the system installation. Operation of control valves and positioners through their entire range, fully stroke the

O O O O O

O O O

O O O O O O O O

O O

Doc. No. : 6261 A 100 920 -001 Annexure : 1

< Security Level 2 > MECHANICAL COMPLETION PROCEDURE

HPCL, Visakh ISSUED : 08.09.2008 Doc. No. : 6261A100920-001
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 HDHT PROJECT

BEFORE MECHANICAL COMPLETION

Sheet 17of 18
AFTER MECHANICAL COMPLETION

WORK ITEM (As per Applicability of Scope of Work)

REMARKS

(c)

(d) (19)

(20) (21)

(22)

valve fully and verify. The instrument systems capability to measure, operate, stroke, etc., in the direction and manner required by the process application. Provide assistance to DCS contractor during loop checking Set and position all control mode adjustments, manual/automatic switches, manually operated valves, all the safety system components, to the correct position for plant start up. Fine tune the instrument systems during start up. Fully pressurise and energise all the control signal and transmitting systems. Open all the specified valving so as to connect the primary sensors and final regulators to line fluids. Conduct the control mode settings for automatic operation of equipment as the process unit is charged and brought on stream. Insulation (if applicable) Complete all the hot, cold and personnel protection insulation and weatherproofing, where the insulation is required for heat conservation or protection, safety and the correct operation during PRECOMMISSIONING. Complete all the insulation and cladding, except for any spool pieces on equipment, which will be disconnected or removed for flushing. Complete all the insulation and cladding, except for any flange connections, valves, equipment manholes and handholes, where the leak check will be conducted during the Overall Tightness Test. Complete all the remaining hot and cold insulation upon completion of the flushing and the Overall Tightness Test.

2.5 (a)

(b)

(c)

(d)

Doc. No. : 6261 A 100 920 -001 Annexure : 1

< Security Level 2 > MECHANICAL COMPLETION PROCEDURE

HPCL, Visakh ISSUED : 08.09.2008 Doc. No. : 6261A100920-001
TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 HDHT PROJECT

BEFORE MECHANICAL COMPLETION

Sheet 18of 18
AFTER MECHANICAL COMPLETION

WORK ITEM (As per Applicability of Scope of Work)

REMARKS

2.5.2 (a)

(b)

(c) (d) (e)

Painting Complete all the painting of equipment and piping, except for minor touch-up of any damaged portions. Complete the painting of the structural steel, except for minor touch-up of any damaged areas, and the intermediate and final coats of the chequered plate upper surfaces. Complete all painting of the equipment and piping, including touch-up of damage. Complete all painting of the structural steel, including touch-up of any damage. Paint the identification marking on piping and equipment. Removal of scaffolding Remove all scaffolding for the insulation and painting works, to the extent that the remaining will not disrupt the activities of PRE-COMMISSIONING and/or COMMISSIONING. Remove all the scaffolding. Fire proofing by guniting or by fixing boards Complete all fire-proofing work of Static Equipment by Guniting as per specification or with any fire proofing material House keeping and ground levelling Clearing of all debris, cleaning all static and rotary equipment of any oil stains, paint marks etc. and removal of excess material from site

O O O

2.5.3 (a)

(b) 2.5.4

2.5.5

Doc. No. : 6261 A 100 920 -001 Annexure : 1