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Mechanical Completion

Mechanical completion is a milestone achieved when all specified work is complete and subsequent acceptance inspection and physical testing is satisfactorily performed and documented. Typically, inspection and testing activities performed to achieve mechanical completion will be carried out on a single discipline basis, by construction workpacks, building to systems / subsystems. Such activities will not require equipment or systems to be energised, but may include bench calibration of instruments, electrical insulation tests, electrical continuity tests, hydrotesting of pipes and integrity testing of valves. Mechanical completion will be documented on checksheets which will be generated and managed by the Project Certifications and Commissioning Management Systems1 to ensure that asset integrity can be verified and demonstrated. On achievement of mechanical completion, responsibility for the facility will transfer from those responsible for construction to those responsible for pre-commissioning and commissioning. MECHANICAL COMPLETION MECHANICAL COMPLETION for SULPHUR BENTONITE PLANT is defined as the date at which SULPHUR BENTONITE PLANT after mechanical erection and precommissioning are ready for acceptance of feed to be introduced to and can continue to receive feed leading to production of Sulphur Bentonite. MECHANICAL COMPLETION shall include completion of all required activities of mechanical erection and pre-commissioning including but not limited to the following activities: i) SULPHUR BENTONITE PLANT or the portion there of is installed in accordance with the drawings, specifications, and contracts, including any approved changes thereto, and in accordance with all applicable codes and laws. ii) All coded pressure equipment is hydrostatically or pneumatically tested once either in the supplier's shop or in the field in accordance with applicable codes or purchase specifications. iii) Fired heaters / boilers are hydrostatically or pneumatically tested. All non-operating pre-firing checks are made in accordance with manufacturer's instructions. Operation of registers and dampers is checked and position of indicators verified. iv) Compressor, Pumps, machinery and all drives are cold aligned. Couplings are assembled and guards installed. v) Instruments are installed, inspected, and such non-operating checks are made as to assure operability in the manner required for the process application. Instrument air lines are checked for correct hook-up. Air lines are leak-tested. Orifice plates are checked for correct bore diameter, ready for OWNER'S installation after completion of flushing operations. vi) Relief valves are installed. Prior to this, they will have been checked by the Contractor in the VENDOR'S shop and rechecked at SITE. vii) Piping is hydrostatically or pneumatically tested in accordance with the specifications. Special treatment, such as chemical cleaning, is done as required by the drawings or specifications. Suction screens are installed. Test blinds are

viii)

ix) x) xi) xii)

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removed. Spring supports, anchors, and guides are checked for removal of all shipping and erection stops and for correctness of cold settings. The electrical system is installed, integrating with the electrical system of PROJECT and tested in accordance with and to the extent required by the electrical specifications. All wiring is checked for correct hook-up. Motor rotation is checked. All power system protective devices are set. Insulation is complete to the extent necessary to permit the start of commissioning and start-up. Painting is completed to the extent that the incomplete work does not prevent the start of commissioning and start up. All inert packing and bed support materials such as raschig rings and alumina balls be installed. Temporary construction facilities are removed to the extent necessary to permit the start of commissioning and start-up

Pre-commissioning The following is a list of typical work performed including but not limited to, after SULPHUR BENTONITE PLANT is mechanically complete  Materials and labour are provided to flush, grease, pack, and lubricate all pumps, compressors, other machinery, and their drives.  All machinery and drives are run-in, hot-checked for alignment, and doweled. Necessary adjustments are made as result of running-in, including resetting turbine over speed trips.  Control valves are installed. Instruments, analysers, controls, interlocks, alarms, and related items are commissioned, including operating checks, provision and installation of seal fluids are required, checking and adjusting settings, standardising, and calibration and proof tests.  Electrical relays and trips are commissioned and tested.  Feedstock, refrigerants, utilities, catalysts, and chemicals are supplied, handled, installed, and prepared for operation, including any catalyst preparation procedures.  Valves are lubricated, packed or re-packed, adjusted, or otherwise serviced.  Temporary strainers are removed, cleaned, and reinstalled.  Slip blinds required in preliminary circulation and start-up lines are installed and removed.  Equipment and lines are flushed, purged, blown, and dried as required for cleanliness, safety, and process considerations. All flanges are boxed up with proper gaskets.  Final adjustments are made to pipe, supports and hangers.  All fire protection and safety facilities are commissioned and put into operation and all safety provisions initiated, including practices, procedures, permits, and other precautionary measures needed to ensure the safety of personnel and property. As soon as MECHANICAL COMPLETION has been achieved, CONTRACTOR shall present SULPHUR BENTONITE PLANT for inspection and on being satisfied about its completion, OWNER shall issue a certificate to CONTRACTOR within 7 DAYS indicating the date of MECHANICAL COMPLETION, provided SULPHUR BENTONITE PLANT can continue to receive feed leading to production of SULPHUR BENTONITE.

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CONTRACTOR shall ensure that MECHANICAL COMPLETION as defined in the bar chart as per the Contract

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TYPICAL MECHANICAL COMPLETION ACTIVITIES

Note: Definition of Mechanical completion, Pre-commissioning & Commissioning is subject to change as per contract specification and contract agreement 1.1.2

MECHANICAL

a) Fabrication completeness b) Equipment Installation & completeness c) Valves pre-testing d) Visual inspection of Equipment & Piping for alignment e) Cleaning of Pipe, Pipeline, Equipment internals f) Hydro testing / Pneumatic Testing g) Flushing, Swabbing, Drying h) Internal inspection of tanks and vessels. i) Load testing of lifting equipment j) Gasket Insertion k) Bolt Torquing / Tensioning l) Leak (Flange) Testing m)Dimension control n) Preservation. 1.1.3

ELECTRICAL

a) Visual inspection for complete and correct installation b) Insulation and continuity testing of cables c) Insulation testing of generator, transformers and motors, panels, distribution board etc d) e) f) g)

Cable Termination, glanding, labeling / tagging Earthing checks Static check of switches and control devices Battery installation, charging & discharging, other related preparations (as relevant and applicable) h) Lighting and socket outlet checks i) Area completion j) Preservation 1.1.4

INSTRUMENT /TELECOMMUNICATION

a) b) c) d) e) f)

Calibration and testing of instruments prior to installation Visual inspection for complete and correct installation Insulation and continuity testing of cables Cleaning, flushing, pressure and leak testing of pneumatic and hydraulic tubing Adjustment of control, alarm and shutdown settings Loop testing

g) h) i) j) 1.1.5

PIPING

a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) 1.6.1

Function testing of control systems Function testing of field instruments Area completion Preservation

Welding procedures Non Destructive Examination(NDE) carried out Removal of all items subject to damage during flushing, cleaning and pressure testing Flushing of pipe work Chemical(corrosion inhibitor) cleaning and testing of pipe work Drying of tested pipe work Preservation (as applicable) of tested pipe work Reinstatement of all items after testing Final inspection of pipe work As built drawing mark-up Marked up isometrics and P&ID's showing the extent of each hydrostatic pressure test Bolt Torquing / Tensioning Pipe supports completed Insulation / Fire Proofing Flow coding

Pre-Commissioning

Pre-commissioning2 activities undertaken after mechanical completion, but prior to commissioning, are to prove and validate the functioning of equipment. Such activities could involve the introduction of fluids into systems, but not hydrocarbons. Typically, pre-commissioning activities will verify that documentation to support mechanical completion is in place, and not repeat work carried out to achieve mechanical completion. Such activities are carried out on a single discipline basis, by system / subsystem, and require equipment or systems to be energised, but do not require the introduction of process fluids. Activities include instrument loop checks, panel function tests, energising electrical equipment and running motors without loads. They are documented on checksheets, which will also be generated and managed by the Project Certifications and Commissioning Management System (CCMS) to ensure that asset integrity can be verified and demonstrated. At the start of pre-commissioning the Completions Management System (CMS) needs to be ready, operational and maintained up to date and the commissioning Permit to Work (PTW) System3 activated. Normal dump flushing is typically a construction activity but specialist flushing and cleaning, e.g. chemical and hydraulic cleaning, drying, oxygen freeing etc, falls within the integrated Commissioning Team’s responsibility. 2

Utility and life support systems could be pre-commissioned and commissioned prior to the pre Startup audit. 3

For Brownfield projects that are being carried out concurrent with operational systems the Operations PTW system will be used.