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Document No.

GP 32-20
Applicability Group
Date Draft 20 April 2007

GP 32-20

Site Inspection, Testing, and


Commissioning of Plant and Facilities

Group Practice

BP GROUP
ENGINEERING TECHNICAL PRACTICES
Draft 20 April 2007 GP 32-20
Site Inspection, Testing, and Commissioning of Plant and Facilities

Foreword

This is the first issue of Engineering Technical Practice (ETP) GP 32-20. This Group Practice (GP) is
based on parts of heritage documents from the merged BP companies as follows:

Amoco (ACES)
A CO-PCOM-GEN-E CommissioningPre-CommissioningGeneralSpecification.
A CO-PCOM-GEN-G CommissioningPre-CommissioningGeneralGuide.
A EL-PCOM-00-C ElectricalPre-CommissioningConstruction Specification.
A FE-PCOM-00-C Fabricated EquipmentPre-CommissioningConstruction
Specification.
A PC-PCOM-IN-C Process ControlCheckout and Pre-CommissioningInstrumentation
Construction Specification.
A PN-PCOM-00-C PipingPre-CommissioningConstruction Specification.

ARCO (APCES)
ES 211-90 Piping Fabrication, Inspection, and Testing.
ES 316-90 Instrument Calibration, Certification, and Commissioning.
ES 408-91 Electrical Testing and Inspection.

British Petroleum (RPSE)


RP 32-2 Site Inspection, Testing and Precommissioning of New Plant.

BP Exploration
Guidance On Certification - Western Hemisphere.
Guidance On Certification - Eastern Hemisphere (UKCS-TI-019).

Copyright 2007, BP Group. All rights reserved. The information contained in this
document is subject to the terms and conditions of the agreement or contract under which
the document was supplied to the recipients organization. None of the information
contained in this document shall be disclosed outside the recipients own organization
without the prior written permission of BP Group, unless the terms of such agreement or
contract expressly allow.

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Table of Contents
Page
Foreword ........................................................................................................................................ 2
1. Scope .................................................................................................................................. 13
2. Normative references........................................................................................................... 13
3. Terms and definitions........................................................................................................... 17
4. Symbols and abbreviations .................................................................................................. 20
5. Roles and responsibilities .................................................................................................... 24
5.1. Certification coordinator ............................................................................................ 24
5.2. Certification manager................................................................................................ 24
5.3. Certification project engineer..................................................................................... 24
5.4. Certification technician .............................................................................................. 24
5.5. Certification trainer.................................................................................................... 24
5.6. Commissioning/certification administrator/coordinator .............................................. 25
5.7. Commissioning authority........................................................................................... 25
5.8. Construction and installation authority....................................................................... 26
5.9. Design authority or engineering manager ................................................................. 27
5.10. Inspector................................................................................................................... 27
5.11. Operator ................................................................................................................... 28
5.12. Operating authority ................................................................................................... 28
5.13. Witnessing authority.................................................................................................. 28
6. Safety .................................................................................................................................. 28
7. Receiving and storage ......................................................................................................... 30
7.1. Receiving .................................................................................................................. 30
7.2. Storage ..................................................................................................................... 31
8. Documentation..................................................................................................................... 32
8.1. General..................................................................................................................... 32
8.2. Records .................................................................................................................... 32
8.2.1. Handover certification package (HCP)......................................................... 32
8.2.2. Separate system documentation ................................................................. 33
8.2.3. System certification ..................................................................................... 34
8.2.4. Commissioning procedures ......................................................................... 35
8.2.5. As built system status.................................................................................. 35
8.2.6. Engineering queries .................................................................................... 35
8.2.7. Punch list .................................................................................................... 35
9. Inspection, testing, and commissioning - general requirements ........................................... 36
9.1. General..................................................................................................................... 36
9.2. Competence ............................................................................................................. 37
9.3. Test dossier .............................................................................................................. 37
9.4. Certification of procured items................................................................................... 38
9.5. Inspection and test program...................................................................................... 39
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9.6. Test equipment calibration ........................................................................................ 39


9.7. Preservation and cleanliness .................................................................................... 40
9.8. Material identification ................................................................................................ 40
9.8.1. Scope and applicability................................................................................ 40
9.8.2. Material certification .................................................................................... 40
9.8.3. Test methods and equipment ...................................................................... 41
10. Welding and NDE ................................................................................................................ 41
10.1. Authorities and definitions ......................................................................................... 41
10.1.1. General ....................................................................................................... 41
10.1.2. Welder qualifications ................................................................................... 41
10.1.3. NDE qualifications ....................................................................................... 41
10.2. Weld inspection ........................................................................................................ 41
10.2.1. General ....................................................................................................... 41
10.2.2. Welding ....................................................................................................... 42
10.2.3. NDE ............................................................................................................ 43
10.3. Certification............................................................................................................... 44
10.3.1. General ....................................................................................................... 44
10.3.2. Ultrasonic report.......................................................................................... 44
10.3.3. Magnetic particle and liquid dye penetrant report ........................................ 44
10.3.4. Radiographic report..................................................................................... 44
10.3.5. Welding and bolt up completion summary ................................................... 44
10.3.6. Heat treatment report .................................................................................. 44
10.3.7. Qualification test record............................................................................... 45
10.3.8. Welder approval test certificate ................................................................... 45
10.3.9. Summary of approved welders .................................................................... 45
10.3.10. Summary of approved weld procedures ...................................................... 45
10.3.11. Summary of approved NDE technicians ...................................................... 45
10.3.12. Summary of approved NDE procedures ...................................................... 45
10.3.13. Weld repair register ..................................................................................... 45
11. Piping .................................................................................................................................. 46
11.1. Inspection and testing ............................................................................................... 46
11.1.1. Scope.......................................................................................................... 46
11.1.2. Identification and marking............................................................................ 46
11.1.3. Inspection during prefabrication, fabrication, erection, and piping completion46
11.1.4. Cleaning and preliminary flushing for pressure testing ................................ 49
11.1.5. Pressure testing .......................................................................................... 54
11.1.6. Mechanical joint integrity ............................................................................. 60
11.1.7. Critical joint installation ................................................................................ 64
11.1.8. Prefabricated pipework................................................................................ 64
11.1.9. Closure welds.............................................................................................. 65
11.1.10. Post test reinstatement and completion....................................................... 65
11.1.11. Nonmetallic pipe.......................................................................................... 67
11.1.12. Drain lines ................................................................................................... 68
11.1.13. Certification ................................................................................................. 70
11.2. Commissioning ......................................................................................................... 70
11.2.1. General ....................................................................................................... 70
11.2.2. System flushing........................................................................................... 70
11.2.3. Leak testing (tightness test)......................................................................... 75
11.2.4. Service testing............................................................................................. 79
11.2.5. Joint integrity testing.................................................................................... 80
11.2.6. Certification ................................................................................................. 81
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12. Unfired pressure vessels ..................................................................................................... 81


12.1. Inspection and testing ............................................................................................... 81
12.1.1. Scope.......................................................................................................... 81
12.1.2. Site fabricated vessels ................................................................................ 81
12.1.3. Offsite fabricated vessels ............................................................................ 81
12.1.4. All vessels ................................................................................................... 82
12.1.5. Site pressure testing.................................................................................... 83
12.1.6. Fractionation columns ................................................................................. 85
12.1.7. Certification ................................................................................................. 85
12.2. Commissioning ......................................................................................................... 86
12.2.1. General ....................................................................................................... 86
12.2.2. Joint integrity testing.................................................................................... 86
12.2.3. Certification ................................................................................................. 86
13. Heat exchange equipment ................................................................................................... 86
13.1. Inspection and testing ............................................................................................... 86
13.1.1. Scope.......................................................................................................... 86
13.1.2. Requirements.............................................................................................. 86
13.1.3. Site pressure testing.................................................................................... 87
13.1.4. Post test remedial work and reinstatement .................................................. 87
13.1.5. Certification ................................................................................................. 88
13.2. Commissioning ......................................................................................................... 88
13.2.1. General ....................................................................................................... 88
13.2.2. Air coolers ................................................................................................... 88
13.2.3. Leak testing (tightness test)......................................................................... 88
13.2.4. Joint integrity testing.................................................................................... 88
13.2.5. Certification ................................................................................................. 89
13.3. Post startup performance testing .............................................................................. 89
13.3.1. General ....................................................................................................... 89
13.3.2. Heat exchangers ......................................................................................... 89
13.3.3. Air coolers ................................................................................................... 89
13.3.4. Certification ................................................................................................. 89
14. Fired heaters........................................................................................................................ 89
14.1. Inspection and testing ............................................................................................... 89
14.1.1. Inspection of tubes and headers before and during erection ....................... 89
14.1.2. General requirements.................................................................................. 89
14.1.3. Heater coils with welded on headers or return bends .................................. 90
14.1.4. Heater coils with tubes expanded into headers ........................................... 90
14.1.5. Pressure testing .......................................................................................... 92
14.1.6. Heater linings, air preheaters, ducts, and stacks ......................................... 93
14.1.7. Burners ....................................................................................................... 93
14.1.8. Certification ................................................................................................. 94
14.2. Commissioning ......................................................................................................... 94
14.2.1. General ....................................................................................................... 94
14.2.2. Leak testing (tightness test)......................................................................... 94
14.2.3. Joint integrity testing.................................................................................... 94
14.2.4. Preparation of fired heater for service.......................................................... 95
14.2.5. Certification ................................................................................................. 95
14.3. Post startup performance testing .............................................................................. 95
14.3.1. General ....................................................................................................... 95
14.3.2. Certification ................................................................................................. 95

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15. Tanks................................................................................................................................... 96
15.1. Inspection and testing ............................................................................................... 96
15.1.1. General ....................................................................................................... 96
15.1.2. Materials ..................................................................................................... 97
15.1.3. Foundations ................................................................................................ 97
15.1.4. Welding ....................................................................................................... 97
15.1.5. Erection....................................................................................................... 97
15.1.6. Insulation, painting, and coatings or liners................................................... 98
15.1.7. Safety devices - preliminary ........................................................................ 98
15.1.8. Testing ........................................................................................................ 98
15.1.9. Tanks fabricated offsite ............................................................................... 99
15.1.10. Tanks modified onsite ............................................................................... 100
15.1.11. Certification ............................................................................................... 100
15.2. Commissioning ....................................................................................................... 101
15.2.1. General ..................................................................................................... 101
15.2.2. Leak testing (tightness test)....................................................................... 101
15.2.3. Joint integrity testing.................................................................................. 101
15.2.4. Certification ............................................................................................... 101
15.3. Post startup performance testing ............................................................................ 102
15.3.1. General ..................................................................................................... 102
15.3.2. Certification ............................................................................................... 102
16. Machinery .......................................................................................................................... 102
16.1. Inspection and testing ............................................................................................. 102
16.1.1. General ..................................................................................................... 102
16.1.2. Certification, preliminary inspection, and preservation............................... 102
16.1.3. Foundations and supporting steelwork ...................................................... 102
16.1.4. Installation................................................................................................. 102
16.1.5. Skid mounted units.................................................................................... 104
16.1.6. Certification ............................................................................................... 105
16.2. Commissioning ....................................................................................................... 105
16.2.1. General ..................................................................................................... 105
16.2.2. Alignment .................................................................................................. 105
16.2.3. Leak testing (tightness test)....................................................................... 108
16.2.4. Joint integrity testing.................................................................................. 108
16.2.5. Running (dynamic testing)......................................................................... 109
16.2.6. Certification ............................................................................................... 109
16.3. Post startup performance testing ............................................................................ 110
16.3.1. General ..................................................................................................... 110
16.3.2. Certification ............................................................................................... 110
17. Structural ........................................................................................................................... 110
17.1. Inspection and testing ............................................................................................. 110
17.1.1. General ..................................................................................................... 110
17.1.2. Certification ............................................................................................... 111
18. Heating, ventilation, and air conditioning............................................................................ 112
18.1. Inspection and testing ............................................................................................. 112
18.1.1. Scope........................................................................................................ 112
18.1.2. Installation................................................................................................. 112
18.1.3. General ..................................................................................................... 112
18.1.4. Dampers ................................................................................................... 114
18.1.5. Filtration .................................................................................................... 115
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18.1.6. Heating and cooling coils........................................................................... 116


18.1.7. Centrifugal fans and drivers....................................................................... 117
18.1.8. Humidifiers ................................................................................................ 118
18.1.9. Constant volume terminal reheat units, grills, and diffusers ....................... 118
18.1.10. Air conditioning units ................................................................................. 119
18.1.11. Air handling unit ........................................................................................ 120
18.1.12. Ductwork ................................................................................................... 120
18.1.13. Sound attenuators ..................................................................................... 121
18.1.14. Cooling towers .......................................................................................... 122
18.1.15. Areas receiving HVAC............................................................................... 123
19. Civil inspection and testing................................................................................................. 123
19.1. General 123
19.2. Civil work ................................................................................................................ 123
19.2.1. Scope........................................................................................................ 123
19.2.2. General ..................................................................................................... 124
19.2.3. Soils and earthwork................................................................................... 124
19.2.4. Piling operations........................................................................................ 125
19.2.5. Concrete ................................................................................................... 125
19.3. Steel construction ................................................................................................... 126
19.4. Piping 126
19.5. Certification............................................................................................................. 126
19.5.1. Civil acceptance ........................................................................................ 126
19.5.2. Civil work................................................................................................... 127
19.6. Buildings, fittings, and furnishings (architectural) .................................................... 128
19.6.1. General ..................................................................................................... 128
19.6.2. Inspection requirements ............................................................................ 128
19.6.3. Surface finish ............................................................................................ 128
19.6.4. Windows and doors................................................................................... 129
19.6.5. Fittings ...................................................................................................... 129
19.6.6. Safety items .............................................................................................. 129
19.6.7. Soft furnishings ......................................................................................... 130
19.6.8. Certification for buildings, fittings, and furnishings (architectural)............... 130
20. Mechanical handling (lifting) equipment ............................................................................. 130
20.1. Inspection and testing ............................................................................................. 130
20.1.1. Overview ................................................................................................... 130
20.1.2. Cranes ...................................................................................................... 133
20.1.3. Hoists, trolleys, and gantries ..................................................................... 135
20.1.4. Trolley beams and pad eyes ..................................................................... 136
20.1.5. Lifeboat davits and lifeboat........................................................................ 137
20.2. Commissioning ....................................................................................................... 138
20.2.1. General ..................................................................................................... 138
20.2.2. Statutory load testing................................................................................. 138
20.2.3. Certification ............................................................................................... 139
21. Painting, coatings, and insulation....................................................................................... 139
21.1. Inspection and testing ............................................................................................. 139
21.1.1. General ..................................................................................................... 139
21.1.2. Painting and coating inspection ................................................................. 139
21.1.3. Insulation inspection.................................................................................. 141
21.1.4. Passive fire protection (PFP) inspection .................................................... 141
21.1.5. Certification ............................................................................................... 141
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22. Electrical (NEC) ................................................................................................................. 142


22.1. Inspection and testing ............................................................................................. 142
22.1.1. General ..................................................................................................... 142
22.1.2. Installation................................................................................................. 143
22.1.3. Preacceptance .......................................................................................... 143
22.1.4. Power, control, and instrument cables....................................................... 145
22.1.5. Switchgear, motor control centres, and metal enclosed bus duct .............. 156
22.1.6. Circuit breakers - air, moulded case, vacuum, and oil immersed ............... 164
22.1.7. Contactor starters...................................................................................... 171
22.1.8. Medium voltage air switches ..................................................................... 174
22.1.9. Power transformers - oil filled and dry type................................................ 176
22.1.10. Lighting and small power distribution systems........................................... 184
22.1.11. Neutral grounding resistors ....................................................................... 188
22.1.12. Heat trace cables and circuits.................................................................... 190
22.1.13. Grounding and bonding............................................................................. 193
22.1.14. Equipment in hazardous locations............................................................. 195
22.1.15. Oil insulation tests ..................................................................................... 198
22.1.16. Instrument transformer verification ............................................................ 198
22.1.17. Junction box inspection ............................................................................. 200
22.1.18. Protective relay and metering circuit testing .............................................. 201
22.1.19. Cathodic protection (CP) systems ............................................................. 203
22.2. Commissioning ....................................................................................................... 206
22.2.1. General ..................................................................................................... 206
22.2.2. Energisation and commissioning ............................................................... 207
22.2.3. Permit to work procedures......................................................................... 208
22.2.4. Safety precautions..................................................................................... 208
22.2.5. Temporary installations ............................................................................. 208
22.2.6. Motors, AC induction and synchronous ..................................................... 209
22.2.7. AC generators ........................................................................................... 214
22.2.8. Variable speed drives................................................................................ 219
22.2.9. Batteries and battery chargers................................................................... 224
22.2.10. Uninterruptible power supplies .................................................................. 227
22.2.11. Navigation aids.......................................................................................... 231
22.2.12. Drying electrical rotating machinery........................................................... 232
23. Electrical (IEC and CENELEC) .......................................................................................... 234
23.1. Inspection and testing ............................................................................................. 235
23.1.1. General ..................................................................................................... 235
23.1.2. Installation................................................................................................. 236
23.1.3. Preacceptance .......................................................................................... 236
23.1.4. Power and control cables .......................................................................... 237
23.1.5. Switchboards and busbars ........................................................................ 241
23.1.6. Circuit breakers ......................................................................................... 245
23.1.7. Contactor starter circuits............................................................................ 246
23.1.8. Fuse switches ........................................................................................... 249
23.1.9. Power transformers ................................................................................... 250
23.1.10. Lighting and small power distribution systems........................................... 253
23.1.11. Neutral earthing resistors .......................................................................... 255
23.1.12. Heat tracing tapes and circuits .................................................................. 256
23.1.13. Earthing (grounding) and bonding ............................................................. 258
23.1.14. Equipment for hazardous locations ........................................................... 259
23.1.15. Oil insulation tests ..................................................................................... 262
23.1.16. Instrument transformer verification ............................................................ 263
23.1.17. Junction box inspection ............................................................................. 265

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23.1.18. Testing of protective relays and meter circuitry testing .............................. 269
23.1.19. Cathodic protection (CP) systems ............................................................. 271
23.2. Commissioning ....................................................................................................... 274
23.2.1. General ..................................................................................................... 274
23.2.2. Energisation and commissioning ............................................................... 274
23.2.3. Permit to work procedures......................................................................... 275
23.2.4. Safety precautions..................................................................................... 276
23.2.5. Temporary installations ............................................................................. 276
23.2.6. Motors, AC induction and synchronous ..................................................... 277
23.2.7. Variable speed drives................................................................................ 280
23.2.8. Batteries and battery chargers................................................................... 285
23.2.9. Uninterruptible power supplies .................................................................. 287
23.2.10. Navigation aids.......................................................................................... 289
23.2.11. Drying electrical rotating machinery........................................................... 290
24. Instrumentation and control systems.................................................................................. 292
24.1. Inspection and testing ............................................................................................. 292
24.1.1. Scope........................................................................................................ 292
24.1.2. General ..................................................................................................... 294
24.1.3. Instrument and control system inspection and storage .............................. 294
24.1.4. Roles and responsibilities.......................................................................... 296
24.1.5. Impulse line pressure testing ..................................................................... 297
24.1.6. Control cable and fibre optic cable testing ................................................. 302
24.1.7. General calibration, installation, and cold loop checking............................ 304
24.2. Commissioning ....................................................................................................... 326
24.2.1. General ..................................................................................................... 326
24.2.2. Instrument and control certification ............................................................ 327
24.2.3. Fieldbus Foundation commissioning.......................................................... 327
24.2.4. Powered up loop and function testing........................................................ 338
24.2.5. System control (function) testing ............................................................... 343
24.2.6. Protective function tests IL a, 1, 2, 3, 4 and HIPPS ................................ 346
24.2.7. Programmable logic controller panels (PLCP) ........................................... 348
24.3. Post startup performance testing ............................................................................ 350
24.3.1. General ..................................................................................................... 350
24.3.2. Certification ............................................................................................... 350
25. Pressure safety valves and bursting discs ......................................................................... 355
25.1. Inspection and testing ............................................................................................. 355
25.1.1. Scope........................................................................................................ 355
25.1.2. Storage, handling, and identification.......................................................... 355
25.1.3. Initial temporary installation ....................................................................... 355
25.1.4. Cleaning, testing, and setting .................................................................... 356
25.1.5. Pilot operated safety relief valves .............................................................. 357
25.1.6. Rupture discs ............................................................................................ 357
25.1.7. Final installation ........................................................................................ 358
25.1.8. Certification ............................................................................................... 358
25.2. Commissioning ....................................................................................................... 358
25.2.1. General ..................................................................................................... 358
25.2.2. Leak testing (tightness test)....................................................................... 358
25.2.3. Joint integrity testing.................................................................................. 358
25.2.4. Certification ............................................................................................... 359
26. Fire, gas, and safety .......................................................................................................... 359

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27. Post startup plant performance testing............................................................................... 359


27.1. General 359
27.2. Certification............................................................................................................. 360
Annex A (Informative) GOC Certificate List ................................................................................. 361
Section 1 System principles ...................................................................................... 361
Section 2 Welding & NDE ......................................................................................... 361
Section 3 Piping ........................................................................................................ 361
Section 4 Mechanical equipment .............................................................................. 361
Section 5 Structural................................................................................................... 361
Section 6 Heating Ventilation Air Conditioning (HVAC) ............................................. 361
Section 7 Architectural .............................................................................................. 362
Section 8 Controls (Instruments, F&G, telecoms)...................................................... 362
Section 9 Electrical (NEC)......................................................................................... 362
Section 9 Electrical (IEC & CENELEC) ..................................................................... 363
Section 10 Civil ........................................................................................................... 363
Bibliography ................................................................................................................................ 365

List of Tables

Table 1 - Test equipment calibration ............................................................................................. 39


Table 2 - Tube rolling chart ........................................................................................................... 91
Table 3 - Rolled tube connection with seal welding ....................................................................... 92
Table 4 - U.S. standard fastener torque values for electrical connections ................................... 147
Table 5 - Insulation resistance test.............................................................................................. 150
Table 6 - High voltage DC test values ......................................................................................... 150
Table 7 - Minimum acceptance insulation resistance .................................................................. 159
Table 8 - AC LV switchgear (voltage and insulation levels) ......................................................... 159
Table 9 - AC MV switchgear (voltage and insulation levels) ........................................................ 159
Table 10 - AC bus duct DC test voltage levels ............................................................................ 160
Table 11 - AC bus duct overpotential (hipot) test voltage levels .................................................. 160
Table 12 - Moulded case breaker overcurrent trip test ................................................................ 166
Table 13 - Insulation resistance conversion factors for test temperature to 20C (68F) ............. 179
Table 14 - Overpotential test voltage for power and distribution transformers ............................. 180
Table 15 - Applied potential test voltage ..................................................................................... 181
Table 16 - Maximum winding temperature during drying ............................................................. 211
Table 17 - Winding megger test voltage and minimum values..................................................... 216
Table 18 - Typical drying curve ................................................................................................... 233
Table 19 - Insulation resistance test............................................................................................ 240
Table 20 - Minimum insulation resistance values ........................................................................ 240
Table 21 - High voltage DC test values ....................................................................................... 241
Table 22 - Minimum acceptable insulation resistance ................................................................. 243
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Table 23 - Power frequency voltage test levels ........................................................................... 244


Table 24 - High voltage DC test levels ........................................................................................ 244
Table 25 - Minimum insulation resistance for transformers ......................................................... 252
Table 26 - Transformer DC pressure test voltage........................................................................ 253
Table 27 - Inspection schedule for Ex d, Ex e, and Ex n installations................................... 266
Table 28 - Inspection schedule for Ex i installations.................................................................. 268
Table 29 - Inspection schedule for Ex p installations ................................................................ 269
Table 30 - Typical drying curve ................................................................................................... 291
Table 31 - Cable test voltage and minimum insulation resistance ............................................... 304
Table 32 - Simulating signals at analogue transmitters ............................................................... 307
Table 33 - Simulating signals at switches.................................................................................... 307
Table 34 - Output verification ...................................................................................................... 308
Table 35 - Checks for different types of temperature switches .................................................... 315
Table 36 - Practical tolerances for orifice diameters.................................................................... 318
Table 37 - Resistance check ....................................................................................................... 330
Table 38 - Capacitance check..................................................................................................... 331
Table 39 - Switch positions check ............................................................................................... 331
Table 40 - DC voltage check ....................................................................................................... 331
Table 41 - Signal level wire condition measurements.................................................................. 332
Table 42 - Noise level wire condition measurements .................................................................. 332
Table 43 - Signal level variation with number of terminations...................................................... 333

List of Forms

Form 22.1 - Conduit installation inspection checkout .................................................................. 152


Form 22.2 - Conduit or cable seal installation inspection checkout ............................................. 153
Form 22.3 - Cable (installed without conduit) inspection checkout .............................................. 154
Form 22.4 - Cable tray installation inspection checkout............................................................... 155
Form 22.5 - Cable blocking kit installation inspection checkout ................................................... 156
Form 22.6 - Electrical switchgear inspection checkout ................................................................ 162
Form 22.7 - Motor control centre inspection checkout................................................................. 163
Form 22.8 - Bus duct inspection checkout .................................................................................. 164
Form 22.9 - Drawout air circuit breaker inspection checkout ....................................................... 171
Form 22.10 - Liquid filled transformer inspection checkout (sheet 1 of 2).................................... 183
Form 22.10 - Liquid filled transformer inspection checkout (sheet 2 of 2).................................... 184
Form 22.11 - Panel board inspection checkout ........................................................................... 187
Form 22.12 - Lighting and receptacle inspection checkout.......................................................... 188
Form 22.13 - Heat trace component inspection checkout (sheet 1 of 2)...................................... 192
Form 22.13 - Heat trace component inspection checkout (sheet 2 of 2)...................................... 193
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Form 22.14 - Electric motor inspection checkout......................................................................... 214


Form 22.15 - AC generator inspection checkout ......................................................................... 219
Form 22.16 - Variable frequency drive inspection checkout ........................................................ 223
Form 22.17 - Battery and battery charger inspection checkout.................................................... 227
Form 22.18 - Uninterruptible power supply inspection checkout.................................................. 230
Form 23.1 - Variable frequency drive inspection checkout .......................................................... 284
Form 24.1 - Fieldbus segment cable checkout form.................................................................... 337
Form 24.2 - Fieldbus cable checkout form with fieldbus wiring monitor ....................................... 338

List of Figures

Figure 1 - Work flow process......................................................................................................... 17


Figure 2 - Waveform with two terminators and 330 m (1 000 ft) cable......................................... 334
Figure 3 - Waveform with one terminator and 330 m (1 000 ft) cable .......................................... 334
Figure 4 - Waveform with three terminators and 330 m (1 000 ft) cable ...................................... 335
Figure 5 - Commissioning control loops flowchart ....................................................................... 351
Figure 6 - Commissioning field switches flowchart ...................................................................... 352
Figure 7 - Commissioning local gages flowchart ......................................................................... 353
Figure 8 - Instrument installation loop check sheet...................................................................... 354

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1. Scope

a. This GP provides guidance for upstream, downstream, and offshore facilities on inspection
and testing (I&T) procedures and commissioning for installations of engineered
equipment.
b. This GP applies to new plant, modifications, maintenance, and plant turnarounds.
c. This GP contains references to BP recommended best practice called Guidance On
Certification (GOC). GOC has been adopted by the BP E&P Major Projects Common
Process as a technical integrity (TI) management tool to define and control inspection and
test activities associated with site fabrication, construction, commissioning, and
maintenance of production facilities being worked upon and handed over for operation.
BP GOC intranet website has more information on this process at:
http://goc.bpweb.bp.com.
Certification documents referenced in this GP (e.g., GOC form MC1) are available
from GOC website. GOC certification documents are the same for the western and
eastern hemisphere editions of the GOC manuals with the exception of those
referenced in the electrical section, clauses 22 and 23 , of this GP. See Annex A for
list of available certificates from the BP GOC intranet website.

2. Normative references

The following normative documents contain requirements that, through reference in this text,
constitute requirements of this technical practice. For dated references, subsequent amendments to, or
revisions of, any of these publications do not apply. However, parties to agreements based on this
technical practice are encouraged to investigate the possibility of applying the most recent editions of
the normative documents indicated below. For undated references, the latest edition of the normative
document referred to applies.

BP
GIS 06-311 Procurement of Cathodic Protection Goods and Services.
GIS 12-501 LV Variable Speed A.C. Drives (IEC).
GIS 12-502 LV A.C. Drives (NEMA).
GIS 12-503 A.C. Drives (IEC).
GIS 12-504 HV A.C. Drives (NEMA).
GIS 30-401 Process Automation Systems (PAS).
GIS 30-402 Programmable Logic Controllers (PLC).
GIS 30-451 Human Machine Interface.
GIS 30-801 Safety Instrumented Systems (SIS).
GIS 30-851 Fire and Gas Detection.
GIS 31-013 Gas Chromatograph Analyser.
GIS 36-103 Positive Material Identification - PMI.
GIS 42-101 Fabrication, Assembly, Erection, and Inspection of Carbon, Carbon
Manganese, and Low Alloy Steel Pipework (ASME B31.3).
GIS 42-102 Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex
Stainless Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and
Zirconium Pipework (ASME B31.3).
GIS 46-040 Supply of Column Internals.
GP 04-10 Drainage Systems and Sewers.
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GP 06-31 Cathodic Protection.


GP 06-32 Cathodic Protection of Onshore Pipelines.
GP 12-25 Earthing/Grounding.
GP 12-50 Variable Speed AC Drives.
GP 12-60 Hazardous Area Electircal Installations.
GP 12-15 Wire and Cable.
GP 14-01 Noise Control.
GP 22-10 Fired Heaters.
GP 30-01 Temperature Instruments.
GP 30-05 Pressure Instruments.
GP 30-10 Non-Fiscal Flow Instruments (Class 2 & 3).
GP 30-20 Miscellaneous Instruments.
GP 30-15 Level Instruments.
GP 30-30 Field Communication Buses.
GP 30-35 Control Valves and Pressure Regulators.
GP 30-40 Process Automation Systems (PAS).
GP 30-45 Human Machine Interface.
GP 30-65 Control Panels.
GP 30-70 Control and Instrumentation in Vendor Packaged Equipment.
GP 30-80 Safety Instrumented Systems (SIS) - Implementation.
GP 30-81 Safety Instrumented Systems (SIS) - Operations and Maintenance.
GP 30-85 Fire and Gas Detection.
GP 30-95 Control Loop Tuning.
GN 32-028 Non-Destructive Examination Methods and Techniques.
GP 32-10 Inspection and Testing of New Equipment in Manufacture.
GP 32-30 Inspection and Testing of Eqipment in Service Management Principles.
GP 32-40 In Service Inspection and Testing Common Requirements
GP 32-47 In Service Inspection and Testing of Mechanical Protective Devices.
GP 42-10 ASME B31.3 Piping Systems.
GP 43-50 Pigging, Pig Launchers, and Receivers.
GP 64-01 Fluid Measurement Management.
BP Golden Rules of Safety (http://hsse.bpweb.bp.com/goldenrules).

Air Movement and Control Association (AMCA)


99-0401 Classifications of Spark Resistant Construction.

American Petroleum Institute (API)


API 510 Pressure Vessel Inspection Code: Maintenance Inspection, Rating,
Repair, and Alteration.
API RP 520 Sizing, Selection and Installation of Pressure-Relieving Devices in
Refineries.
API RP 576 Inspection of Pressure-Relieving Devices.
API RP 1110 Pressure Testing of Liquid Petroleum Pipelines.
API Std 527 Seat Tightness of Pressure Relief Valves (formerly ANSI B147.1).
API Std 650 Welded Steel Tanks for Oil Storage.

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API Std 1104 Welding of Pipelines and Related Facilities.

American Society of Mechanical Engineers (ASME)


ASME B31.3 Process Piping.
ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and other
Liquids.
ASME B31.8 Gas Transmission and Distribution Piping Systems.

American Society for Nondestructive Testing (ASNT)


ASNT SNT-TC-1A Recommended Practice on Nondestructive Testing.

American Society of Testing and Materials (ASTM)


ASTM D1186 Standard Test Methods for Nondestructive Measurement of Dry Film
Thickness of Nonmagnetic Coatings Applied to a Ferrous Base.

American Welding Society (AWS)


AWS-QC1 Standard for AWS Certification of Welding Inspectors.

British Standards Institute (BSI)


BS 161 Tungsten filament lamps for general service (batch testing).
BS 162 Electric power switchgear and associated apparatus.
BS 171 Power transformers.
BS EN 752-4 Drain and sewer systems outside buildings Part 4: Hydraulic design and
environmental considerations.
BS 4999 General requirements for rotating electrical machines.
BS 5227 AC metal-enclosed switchgear and control-gear or rated voltage above
1 kV.
BS 5467:1989 Electric cables thermosetting insulated, armoured cables for voltages of
600/1 000 V and 1 900/3 300 V.
BS 6626:1985 Code of practice for maintenance of electrical switchgear and controlgear
for voltages above l kV and up to and including 36 kV (Replaces
BS 5405).
BS 6346:1989 PVC-insulated cables for electricity supply.
BS 6480:1988 Impregnated paper-insulated lead or lead alloy sheathed electric cables of
rated voltages up to and including 33 000 V.

International Electrotechnical Commission (IEC)


IEC 60079-0 Electrical apparatus for explosive gas atmospheres: Part 0 - General
introduction.
IEC 60079-10 Electrical apparatus for explosive gas atmospheres: Part 11 - Intrinsic
safety e.
IEC 60079-14 Electrical apparatus for explosive gas atmospheres: Part 14 - Electrical
installations in explosive gas atmospheres (other than mines).
IEC 60079-17 Electrical apparatus for explosive gas atmospheres: Part 17 -
Recommendations for inspection and maintenance of electrical
installations in hazardous areas.
IEC 60079-19 Electrical apparatus for explosive gas atmospheres: Part 19 - Repair and
overhaul for apparatus used in explosive atmospheres.

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IEC 60296-3 Fluids for electromechanical applications unused mineral insulating oils
fro transformers and switchgear.

Institute of Electrical and Electronics Engineers (IEEE)


IEEE 43 Recommended Practice for Testing Insulation Resistance of Rotating
Machinery.
IEEE 81 Guide for Measuring Earth Resistivity, Ground Impedance, and Earth
Surface Potentials of a General System.
IEEE 400-1991 Guide for Making High-Direct-Voltage Tests on Power Cable Systems in
the Field.
IEEE 576-2000 Recommended Practice for Installation, Termination, and Testing of
Insulated Power Cable as Used in Industrial and Commercial
Applications.
IEEE C37.09 Standard Test Procedure for AC High-Voltage Circuit Breakers Rated on
a Symmetrical Current Basis.
IEEE C37.20.2 Standard for Metal-Enclosed Switchgear.
IEEE C37.34 Standard Test for High-Voltage Air Switches.
IEEE C57.12.01 General Requirements for Dry Type Distribution and Power
Transformers.
IEEE C57.106 Guide for Acceptance and Maintenance of Insulating Oil in Equipment.

InterNational Electrical Testing Association (NETA)


Acceptance Testing Specification for Electrical Power Distribution
Equipment and Systems.

International Organization for Standardization (ISO)


ISO 4406 Hydraulic fluid power Fluids - Method for coding the level of
contamination by solid particles.

NACE International (NACE)


NACE RP0287 Field Measurement of Surface Profile of Abrasive Blast Cleaned Steel
Surfaces Using a Replica Tape.

National Aerospace Standard (NAS)


NAS 1638 Cleanliness Requirements of Parts Used in Hydraulic Systems.

National Fire Protection Association (NFPA)


NFPA 70 National Electric Code (NEC).
NFPA 70B Recommended Practice for Electrical Equipment Maintenance.
NFPA 496 Standard for Purged and Pressurized Enclosures for Electrical Equipment.

National Electrical Manufacturers Association (NEMA)


NEMA MG-1 Motors and Generators.
NEMA PE 1-2003 Uninterruptible Power Systems (UPS) - Specification and Performance
Verification.
NEMA PE 5-1997 Utility Type Battery Chargers.
NEMA ST 20 Dry-Type Transformers for Utility Applications.

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Society for Protective Coatings (SSPC)


SSPC-PA 2 Measurement of Dry Coating Thickness with Magnetic Gages.
SSPC-Vis 1-89 Guide and Reference Photographs for Steel Surfaces Prepared by Dry
Abrasive Blast Cleaning.
SSPC-Vis 3 Guide and Reference Photographs for Steel Surfaces Prepared by Hand
and Power Tool Cleaning.

3. Terms and definitions

For the purposes of this GP, the following terms and definitions apply:

Construction authority
Construction and installation authority is individual or group:

a. Responsible for ensuring inspections and tests are performed during construction.
b. To help drive area construction activities to system mechanical completion.

Commissioning
Functional checking and testing activities that require system to be powered up and energised as
illustrated in Figure 1.

Figure 1 - Work flow process

Mech completion Function testing System Handover Introduce hydro- Final testing
completed 1. Powered up loop completed carbons or product 1. Testing on
1. Visual tests 1. Function testing hydrocarbons or
inspection 2. Flushing 2. Flushing product if required.
2. Workshop cal of 3. Leak testing 3. Leak testing 2. Performance
any pneumatic 4. Protective system 4. Review of punch testing
instruments end to end test list. All A items 3. Zero check
3. Hydrotests (note 5. Need to completed. transmitters on
1) implement product where
4. Cable IR tested operations PTW necessary.
5. First stage of system as N2,
punching water, power
introduced.
Labelling of live
equipment may be
required.

Construction team

Commissioning team

Notes Operations team Note 2


1. Spades can be left in with the
agreement of the construction and
commissioning authorities. Also
hydrotest water may be used for
flushing.
2. Commissioning team make be
assigned ongoing responsibilities by
operating authority if testing with
hydrocarbons or product is required.

Commissioning is sometimes ambiguously referred to as precommissioning.


Commissioning activities may range from checking, verification, testing, loop
testing, and motor run test of assemblies, loops, or systems to ensure that functional
and operational actions comply with applicable rules, regulations, codes, and
standards and that actions comply with equipment design purpose and intended

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service. Other activities include final testing and adjustment of assembly or system
that consists of operational testing under simulated conditions to ensure that
assembly or system fulfils intended duty and is ready for handover to operations.

Commissioning authority
Individual or individuals responsible for ensuring functional testing and commissioning activities are
performed for system or systems.

Commissioning and certification administrator or coordinator


Performs compilation, verification, and auditing of certification process.

Commissioning engineer
Discipline engineer responsible for assisting in functionality testing or commissioning of system or
systems.

Engineering authority (major project)


Major project engineering authority (EA):

a. Leads and manages technical integrity assurance such that proper management systems are
established in project Select phase and verifies that management systems are properly
implemented throughout project.
b. Ensures that completed product handed over to operations complies with agreed upon
standards and functional requirements.
c. Has role underpinned by BP common practices and standards, EA network support, and
interfaced with BU/SPU EA throughout project.

Guidance On Certification
a. GOC is BP best practice for project completions system that encompasses technical
integrity management for full lifecycle of asset.
b. GOC defines procedural and certification requirements for inspection and test activities for
fabrication, construction, and commissioning, leading to handover of works to operating
authority (OA).
c. GOC is management system that provides fully integrated multidiscipline approach to
planning, execution, and documentation of construction, commissioning, and operational
activities.
GOC details are available on BP intranet site at http://goc.bpweb.bp.com.

Handover certification package


Handover certification pack or package (HCP), also commonly known as system handover book,
contains certification requirements for system that will be handed over to OA. See clause 8 for more
details.

Inspection and testing


a. I&T applies to non energised activities during construction phase of project that leads to
mechanical completion of system or systems.
b. I&T includes checking, verification, calibration, inspection, and testing of construction
work performed by Vendor to confirm compliance with applicable rules, regulations,
standards, and design and construction drawings.
c. I&T examples include powered down cable testing, instrument calibration, welding
nondestructive examination (NDE), and pipe strength hydrotesting.
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Inspector
a. Inspector is individual responsible for monitoring and overseeing inspection and testing of
equipment.
b. Inspector may be construction engineer, plant inspector, welding inspector, or authorised
agency inspector.

Limits of system handover


Limits of system handover (LOSH) are achieved by:

a. Dividing scope of work into standalone operational (functional) systems that perform
specific quantifiable duties.
b. Identifying associated interfaces, piping specification changes, and isolation boundaries
between these systems and other connected systems.

Mechanical completion
a. Mechanical completion (MC) is milestone in construction process that signifies completion
of activities defined in inspection and test plans for construction and installation to
specified project design and standards.
b. MC is a certificate or document signifying verification of inspections and testing have been
completed and accepted.
c. MC is performed before energising components either electrically or by pressure.
d. Test examples include powered down cable testing, instrument calibration, welding NDE,
mechanical equipment installation, alignment, and piping strength hydrotesting.
e. At handover stage, MC handover (GOC form MC1) is signed off upon satisfactory
acceptance by construction and installation authority. This signifies that system is ready for
commissioning and transfer of TI from construction authority to commissioning authority.

Operator
Department responsible for final acceptance and subsequent operation of plant or equipment
installation.

Operating authority
a. Operating authority (OA) is operator representative who needs to be satisfied that
appropriate steps have been taken by performing bodies (i.e., commissioning authority) to
ensure that system offered for acceptance is safe, effective, and operable and that handover
certification pack (HCP) will comply with EA and legislative requirements.
b. OA signs system handover documentation as acceptance of operational system, subject to
constraints or limitations detailed on handover.

Precommissioning
Commissioning scope is sometimes ambiguously referred to as precommissioning.

Plant performance testing


Post system handover activity that verifies design integrity and expectations and that facility is
performing to expectations for agreed upon time period. See clauses 8 and 27 for more details.

Preservation
Preventive maintenance performed on equipment before it is placed into service.

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Punch list
a. List of outstanding items of work or defects relating to original scope of work that need to
be completed or repaired.
b. Marked up piping and instrument diagram (P&ID) generally accompanies punch list item
to show location of incomplete or defective items. See clause 8 for more details.

Startup
Initial introduction of fluids into system and initial operation of system.

During startup, after operations group has assumed responsibility for system,
commissioning provides support in plant optimisation to verify that plant and
equipment meet agreed upon performance standards.

Subsystem
System separated into smaller operational subsystems.

System
a. Operational system that fulfils specific quantifiable duty to be performed by operational
plant.
b. System is dynamic process, facility, or utility, such as oil gas, water systems, control,
electrical, telecom, safety, utility, heating, ventilation, and air conditioning (HVAC), flare
and vent, subsea, wells, and flowlines.

System handover
System handover is milestone within project if specified plant system has been fully tested to project
commissioning procedures and standards and is ready for safe continuous operation.

System handover certificate


a. Certificate or document that signifies commissioning (functionality testing) activities for
partial or complete system have been completed (with exceptions noted) for operator to
safely operate modified or new system.
b. Certificate or document transfers completed system from commissioning authority to OA.

System mnemonics
a. System mnemonics provide numbering system used to track tagged items within each
system.
b. Functional systems are operational systems that provide life of plant value to operations
and maintenance of facility.
c. Mnemonics are provided in form of chart that will define primary and secondary systems
for project.

4. Symbols and abbreviations

For the purpose of this GP, the following symbols and abbreviations apply:

BU Business unit.

CP Cathodic protection.

CT Current transformer.

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d/p Differential pressure.

DBSE Distance between shaft ends.

DCS Distributed control system.

DFT Dry film thickness.

DIS Data input sheet.

DPI Liquid dye penetrant inspection.

DTI Dial test indicator.

EA Engineering authority.

EH Eastern hemisphere.

EQ Engineering query.

ESD Emergency shutdown.

F&G Fire and gas.

FAT Factory acceptance testing.

FF Foundation fieldbus.

GFCI Ground fault circuit interrupter.

GOC Guidance On Certification.

HAZOP Hazard and operability.

HCP Handover certification pack.

HIPPS High integrity pressure protection systems.

HSSE Health, safety, security, and environmental.

HV High voltage.

HVAC Heating, ventilation, and air conditioning.

I/P Current to pressure.

I&T Inspection and testing.

ID Identification.

ID Inside diameter.

IFC Issued for construction (drawings or data sheet).

IRN Inspection release note.

ITS Inspection and test summary.


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JSA Job safety analysis.

LED Light emitting diode.

LOC Letter of conformity.

LOSH Limits of system handover.

LRV Lower range value.

LV Low voltage.

MAOP Maximum allowable operating pressure.

MAWP Maximum allowable working pressure.

MC Mechanical completion.

MCC Motor control centre.

MI Mineral insulated.

MSDS Material safety data sheet.

MT Magnetic particle testing.

MV Medium voltage.

Navaid Navigational aid.

NDE Nondestructive examination.

OA Operating authority.

P&ID Piping and instrument diagram.

PA Public address.

PAH Pressure alarm high.

PAL Pressure alarm low.

PAS Process automation system.

PD Positive displacement.

PFP Passive fire protection.

PI Pressure indicator.

PI Polarization index.

PLC Programmable logic controller.

PLCP Programmable logic controller panel.

PSD Process shutdown.


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PSV Pressure safety valve.

PT Power transformer.

PT Pressure transmitter.

PTFE Polytetrafluoroethylene (e.g., Teflon).

PTW Permit to work.

PWHT Post weld heat treatment.

QP Quality plan.

RD Rupture disk.

RO Restriction orifice.

RT Radiographic testing.

RTD Resistance temperature detector.

SELV Safety extra low voltage.

SIS Safety instrumented system.

SLD Single line diagram.

SPU Strategic performance unit.

SSIV Subsea intervention valve.

SWL Safe working load.

TDC Top dead centre.

TEMPSC Totally enclosed motor propelled survival craft.

TI Technical integrity.

TI Temperature indicator.

TQ Technical query.

UHF Ultrahigh frequency.

UPS Uninterruptible power supply.

URV Upper range value.

UT Ultrasonic testing.

VAC Volts alternating current.

VDC Volts direct current.

VHF Very high frequency.


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VSD Variable speed drive.

WA Witnessing authority.

WH Western hemisphere.

WPS Welding procedure specification.

X Zero sequence reactance.

5. Roles and responsibilities

One important step in establishing roles and responsibilities of various groups


within project is to review responsibility matrix supplied with BP GOC. Matrix
review should be performed as early as possible in project cycle, either during front
end engineering design (FEED) study or early engineering design stage. Significant
advantages can be gained at this stage that might be lost performing review later in
the project lifecycle. Process involves meeting with construction, commissioning,
design, and certification representatives to agree upon who perform which tasks.
Upon agreement, relevant parties can adjust staffing levels to accommodate
responsibilities within completions management process.

5.1. Certification coordinator


Same as certification technician but serves as liaison to management and has ability to manage
small to medium project.

5.2. Certification manager


a. Part time or full time post for major jobs involving team of four or more certification staff
where responsibilities are more stringent, with some management of technicians and
engineers required.
b. Manager typically attends meetings with project management and coordinates efforts
between groups or sites or Contractors.
c. Manager hosts meetings and involves trainers as demands of project develop.

5.3. Certification project engineer


a. Individual or individuals who assist in certification for large or fast track projects.
b. Responsibilities include strategic planning of how to meet and overcome challenges of
schedule and still produce concise record set proving audit trail required and expected by
authorities.

5.4. Certification technician


Technician with responsibilities for keeping inspection and test record set current, running and
issuing reports, inputting data, and providing guidance and advice on how to find files and
complete test records.

5.5. Certification trainer


Main responsibility of certification trainer is to bring level of understanding on expectations of
certification system to general engineering staff on all levels of project by instilling awareness
of importance of inspection and test record set to personnel.

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5.6. Commissioning/certification administrator/coordinator


Commissioning/certification administrator performs compilation, verification, and auditing of
certification process. Role can vary depending on agreement of responsibilities and may include
technicians, inspectors, clerks, manager, or project engineer as required. Principal duties
include:
a. Working with engineering management.
b. Receiving required record sets for entry into GOC database or project completion system
for certification tracking from construction authority, installation authority, or
commissioning authority.
c. Validation of record sets using correct level of discipline engineers either supplied by
client or by certification group.
d. Filing ITS check sheets of data sets into GOC records for audit.
e. Entering or overseeing entry of data into GOC database.
f. Overseeing compilation of HCPs (e.g., system handover books).
g. Identifying and agreeing to list of responsible engineers for signing record set during
construction phase, commissioning phase, and final acceptance authorities from operations
group.
h. Managing punch list process.
i. Verifying certification certificates are properly signed off and data is entered into GOC
database upon certificate completion.
j. Having custody and responsibility to ensure that data in certification database is current
and accurately reflects contents and status of HCPs.
k. Providing management of all groups with status reports of contents and progress of record
set, including I&T activities and handover or system ownership status.
Data set integrity. If responsibility of data set and its relevant accuracy is left to
construction or commissioning group, it is open to fudging, even to point of being
blamed for lack of accurate information. Alternately, if contract model is arranged
such that integrity and accuracy of certification process is separately accountable, it
becomes self checking model. Activities being claimed as complete can easily be
verified by presence (after small time lag) of test and inspection records in
independently run completions management system. This is why BP often uses single
point source of support for GOC completions management system.

5.7. Commissioning authority


Commissioning authority role includes:
a. Providing input into commissioning procedures and function testing in commissioning
phase of project.
b. Participating in MC punch list walk through with construction authority and OA before
handover of system to commissioning authority.
c. At handover stage, signing off MC handover (GOC form MC1) upon satisfactory
acceptance by construction and installation authority. This signifies that system is ready for
commissioning and transfer of TI from construction authority to commissioning authority.
d. Ensuring that safety related punch list items are complete before commencement of
commissioning, including those items necessary to function test system or systems.

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e. Ensuring commissioning activities that include functional system testing are complete for
given partial or complete system and data are entered into project completions system or
GOC database.
f. Performing end of commissioning punch list walk through inspection with OA performing
body (with construction authority invited to participate) before system handover of system
to OA.
g. Ensuring incomplete or outstanding items are entered into master project punch list.
h. At system handover stage, completing and signing off system handover (GOC form SH1)
upon satisfactory completion of commissioning activities of partial or complete systems
and offering to OA for acceptance and signature. This signifies that system is ready to
operate and demonstrates TI has been achieved.
i. Providing input to update project completions database as appropriate.
j. Handing over system, along with requisite completed system handover certification, to
OA.
k. Participating in punch list walk through inspection with operations. Incomplete or
outstanding items shall be noted and entered into punch list database.
l. Managing commissioning process of function testing in safe and orderly manner in
preparation for final handover of each system to operations and, if possible, involving
operations frequently to reduce ambiguity or vagueness to definition and content of system
limits.
m. Transferring ownership of completed system (with minimum outstanding punch list) in
safe and effective manner.
n. Working with operations to ensure that operations are properly prepared and
knowledgeable of systems being handed over and have received correct training to
understand operations of plant.
o. During transfer of ownership, ensuring that locks and isolations are walked down together
with operations and that operations replaces commissioning locks and isolations prior to
signing final acceptance of system handover (GOC form SH1).

5.8. Construction and installation authority


a. Construction and installation authority role
1. Construction and installation authority shall be responsible for ensuring that
designated discipline field engineers sign off appropriate areas on MC certificate to
indicate work completion and that punch lists for their discipline are listed.
2. After construction is complete, punch lists are produced, and project completions
database is updated, as applicable, construction and installation authority shall hand
over systems, along with requisite completed MC certificates, to commissioning
authority.
3. At MC handover stage, construction and installation authority and commissioning
authority (with operations invited to participate) shall perform punch list walk
through inspection. Incomplete or outstanding items shall be noted on discipline
specific punch lists by system.
4. Before system commissioning, construction and installation authority shall ensure
that safety related punch list items are satisfied, including items that require system
function testing.
5. Construction and installation authority may provide entries on DIS for construction or
installation activities.

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6. Construction and installation authority shall be responsible for reviewing DIS


presented by engineering house and sign off I&T summary sheet before data are
entered into GOC database or project completion system.
7. Instead of data entry through DIS, data may be transferred from project discipline
databases. If this is done, construction and installation authority shall review
discipline I&T summaries for accuracy and completion.
b. Construction and installation authority duties include:
1. Providing input for I&T requirements by reviewing I&T scope for each system using
qualified discipline construction engineers.
2. Ensuring that I&T activities during construction phase are properly executed and
recorded on I&T forms and filed by system in HCP and in project completions system
or GOC database.
3. Performing MC punch list walk through inspection with commissioning authority
(and OA invited to participate) before handover of system to commissioning
authority.
4. Ensuring that designated discipline field engineers sign off appropriate discipline
areas on MC certificate to indicate work completion and that punch lists for their
discipline are listed.
5. Ensuring incomplete or outstanding items are entered into master project punch list.
6. At MC handover stage, signing off MC handover (GOC form MC1) upon satisfactory
completion of inspection and test activities of partial or complete systems and
offering MC handover to commissioning authority for acceptance and signature. This
signifies system is ready to start commissioning and demonstrates TI has been
achieved through MC.
7. Participating in punch list walk through with commissioning authority and OA before
system handover to OA.

5.9. Design authority or engineering manager


Individual responsible for initial setup of P&ID and other design drawings. Role includes:
a. Ensuring system limits are accurately recorded on primary design drawings at secondary
system level.
b. Assisting with review of system mnemonics.
c. Assisting with minimum levels of certification definition.
d. Assisting with HCP contents definition.
e. Reviewing inspection and test summary (ITS) reports for system limits.
f. Providing system identification on database records to aid population of tracking database
for disciplines.
g. Providing periodic updates of database records as design matures.

5.10. Inspector
Individual responsible for monitoring and overseeing I&T of equipment, piping, cables, or other
components. Inspector may be construction engineer, plant inspector, welding inspector, or
authorised agency inspector.

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5.11. Operator
Department responsible for final acceptance and subsequent operation of plant or equipment
installation.

5.12. Operating authority


a. Operating authority (OA) shall be satisfied that appropriate steps have been taken by
performing bodies to ensure system offered for acceptance is safe, effective, and operable
and that HCP will meet EA and legislative requirements.
b. OA shall sign system handover (GOC form SH1) as acceptance of operational system,
subject to constraints or limitations detailed on handover.
c. Operations role within certification process should involve close working relations with
both construction and commissioning and may gain many advantages by being involved
throughout design, as well.
d. Operators should be in construction environment and be available as resource to
commissioning team.
Much knowledge and understanding can be gained by this approach, but too often,
training requirements and schedule for operators prevents this from being realised.
e. Operations should try to schedule time to coincide with commissioning such that
operations staff are allowed time to spend on plant during commissioning phase.

5.13. Witnessing authority


a. WA carries the office of regulatory body or an organisation and has hold point requirement
to witness test being performed.
b. Absence of WA after reasonable notice period shall not delay test being performed, but
effort should be made to ensure WA is present for test.
c. WA for electrical inspection and electrical testing and commissioning shall be qualified
electrical person familiar with construction and commissioning of equipment, hazards
involved, and test equipment.

6. Safety

a. Safety shall be primary concern and responsibility of involved personnel for inspection,
testing, and commissioning activities.
b. Personnel shall be qualified to perform their assigned activities.
c. Personnel involved in inspection, testing, and commissioning of systems shall have
experience and verifiable training in these subjects.
d. Personnel shall review, be familiar with, and adhere to relevant portions of BP HSSE
documents and procedures, as well as applicable safety requirements at fabrication,
construction, or integration, or facility site.
e. BP Golden Rules of Safety shall be adhered to by all personnel, including Contractors.
f. Testing shall be performed without introduction of process hydrocarbons.
1. If hydrocarbons are necessary for final system testing, system shall be handed over to
operations with exceptions listed.
2. Commissioning team shall assist operations in final testing during system startup.
g. Before starting work, JSA or equivalent site specific procedure shall be performed to:
1. Confirm that persons involved are trained and competent.
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2. Ensure that appropriate personal protection equipment (PPE) is worn.


3. Review emergency response plans.
4. Emphasise that each person is empowered to stop work if perceived to be unsafe.
h. During commissioning phase, when systems are energised, PTW shall be in place to
authorise commissioning activities.
i. Personnel working within commissioning group shall be fully aware of their duties,
responsibilities, and potential hazards associated with system under test.
j. Individuals shall be trained in PTW procedures and trained to operate specific equipment
they are required to operate during commissioning procedures in accordance with their
roles and duties.
k. Site specific safety, environmental, evacuation, and emergency procedures shall be in
place and communicated to persons involved in inspection, testing, and commissioning
activities.
l. PTWs and lockout tag out procedures shall be kept current and in force.
m. Restrictions of access notices and barriers shall be posted in accordance with PTW system.
n. MSDSs for substances (e.g., chemicals, fluids) that are used shall be readily available on
site and reviewed by involved personnel before proceeding with related commissioning
activity.
o. Safe and efficient commissioning of facility requires systems to be installed completely,
checked for integrity, and commissioned for use. Steps involved in achieving this process
shall be clearly defined, understood, and followed.
p. System specific safety precautions shall be fully defined and incorporated before
commencement of system or equipment testing, including:
1. System boundary isolations shall be listed or illustrated on appropriate drawings.
2. Warnings, cautions, and danger statements shall be listed with each system to be
commissioned.
3. Permit to test job safety analysis checklist
a) In addition to JSA, permit to test job safety analysis checklist or document shall
be presented with each system to commission.
b) Permit to test considers specific safety items that shall be complete before
performing any work.
c) Document shall be initiated by lead commissioning person and shall be reviewed
and signed by discipline leaders either participating in work or potentially
affected by work.
d) Environmental considerations for handling and disposal of any fill or test
materials shall be listed (refer to MSDS).
e) HSSE matrix check sheet
i. HSSE matrix check sheet shall be provided with checklist to define various
work activities as associated with potential areas of risk with weighted risk
assessment against each activity.
ii. Identified high risks shall be eliminated or mitigated to greatest extent
possible and so documented.
q. Before initiating commissioning activities, MC checklists and other appropriate documents
shall be reviewed and confirmed as complete. All components shall be accepted for
subsequent commissioning efforts.
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r. Housekeeping
1. Project shall maintain adequate housekeeping practices as required for safe operation
during construction, MC, and commissioning.
2. All areas of site shall be neat and safe.
3. Excess materials, temporary facilities, and scaffolding that are no longer required
shall be removed.
s. Defective items shall be repaired or replaced.

7. Receiving and storage

7.1. Receiving
Upon receipt, equipment and materials shall be checked for:
a. Compliance with design and purchase specifications.
b. Correct tagging as follows:
1. Equipment items shall be examined to confirm that information on nameplates or tags
is complete and correct.
2. Equipment items shall be examined to confirm their suitability for specified
hazardous area classification for location in which items are to be installed.
c. Shipping damage
1. Thoroughness of check shall be determined by complexity, criticality, and fragility of
item.
2. Shipping damage shall be recorded and condition of packaging shall be noted by
materials and stores department.
3. Photographs shall be taken of damage for documentation.
4. Equipment that is damaged or suspected to be faulty as result of damage to either
equipment or packaging shall be quarantined pending assessment by appropriate
authority.
5. EA shall determine whether damaged equipment may be:
a) Released without further action.
b) Returned to Vendor for repair.
c) Repaired on site, if possible, without invalidating Vendor warranty.
d) EA shall advise materials department accordingly.
6. Inspector shall be advised of damage found and proposed corrective action.
d. Shipping shortage
1. Items shall be checked off against packing list and inspector shall be advised of
shortages.
2. Loose shipped material shall be inspected for shipping damage.
e. Relevant documentation (installation and handling instructions) and declaration of
conformity.
f. Modular and packaged equipment
1. Modular and packaged equipment shall be inspected to confirm that structure, cable,
and piping runs do not conflict with equipment on adjacent modules or units.

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2. Access for commissioning and maintenance shall be checked.


g. Equipment or devices not accompanied by appropriate certification or referenced as being
reviewed and accepted on appropriate ITS shall be quarantined until certification is
available.

7.2. Storage
After inspection, equipment and materials shall be:
a. Replaced in original factory boxes with shipping stops and other devices for protection
against damage while in storage.
b. Checked that they are correctly tagged.
c. Calibrated as follows:
1. To ensure early detection of damage, suitable equipment shall be calibrated in
workshop as soon as practical after receipt into store.
2. Calibration sticker showing calibrated range and setting, date, and responsible person
shall be attached to equipment.
3. Material control department shall be responsible for coordinating this activity.
4. Instruments that have been factory calibrated shall not be recalibrated in field.
Most electronic instruments already come calibrated so there is no need for
calibrating again. If working with small number of trusted Vendors that stand ready
to resolve problems, it may be possible to take instrument out of box, install it, and
power it up.
d. Stored as follows:
1. Devices and materials shall be stored as recommended by Vendor and protected
against adverse weather conditions.
2. If special storage requirements are stipulated, items shall be stored as designated with
shipping stops and protective devices in place.
3. Materials stored under permanent cover shall be on suitable shelving, racks, bins,
spools, or pallets.
4. Materials shall not be stored in direct contact with ground.
5. Openings shall be closed with suitable plugs or screw caps that are securely in place.
6. Integrity of sealed protective covers shall be maintained.
7. If instruments or control panels have been premounted on machinery package and
cannot be stored in dry enclosed area, special arrangements shall be made between
representatives from Vendor and BP.
8. Premounted instruments and control panels that cannot be protected from rain,
humidity, temperature, or dusty conditions shall be removed and placed in indoor
storage.
9. For indoors or controlled atmosphere storage:
a) Sensitive equipment shall be stored in secure, clean, dry, rodent free,
weatherproof, humidity and temperature controlled, largely dust free
environment on shelves in enclosed area.
b) Computers and delicate electronic equipment fall in this category and other
items as specified by Vendor.

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10. For regular indoor storage, equipment and materials shall be protected from weather
and exposure to rain, sun, and general environmental degradation.
11. For outdoors and yard storage, large equipment that cannot be reasonably stored
indoors and will not significantly degrade due to exposure over expected storage
period may be stored outdoors if proper preservation procedures are in place.
12. Exceptions to storage shall be permitted only with expressed written authorisation of
inspector.
13. Refer to project procurement plan for any deviations to above activities or for special
storage requirements.
Explosion proof enclosures are not necessarily weatherproof enclosures because
open conduit connections can allow entrance of moisture. This should have been
addressed during procurement or shop inspection stage but is sometimes
overlooked.

8. Documentation

8.1. General
a. Inspection, testing, and commissioning documentation shall be organised by system.
b. Commissioning activities shall be performed using current edition of following documents:
1. P&ID showing LOSH of each system.
2. Vendor drawings and data sheets.
3. Vendor information as required to ensure that installation, calibration, and checkout
are correct.
4. Vendor support information.
5. Materials and spares required for commissioning.
6. Factory calibration certification.
7. FAT or Vendor IRN form.

8.2. Records

8.2.1. Handover certification package (HCP)


a. HCP may be compiled after system handover limits and associated certification
requirements have been defined and approved.
b. HCP is also commonly known as system handover book.
c. HCP shall contain certification requirements for system that will be handed over to OA.
d. As work progresses, certificates shall be completed and inserted in HCP, and appropriate
I&T plan or database shall be updated accordingly.
e. HCP shall be handed over from one performing authority to another until final handover to
operator.
f. HCP, after final handover, shall then be returned as soon as possible to appropriate asset
engineering group for as built document and drawing, closeout, auditing (if appropriate),
and archiving.
g. HCP shall include following items:
1. Handover documents

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a) System handover certificate.


b) MC certificate.
c) Punch lists by discipline.
d) Cross reference explanatory notes of certification documents.
2. Objective statement.
3. System description, including prerequisite systems and temporary systems.
4. HSSE assessment of systems to be commissioned and permit to test (see clause 6).
5. LOSHs, including:
a) P&IDs.
b) Electrical SLDs.
c) F&G diagrams.
6. Commissioning procedures with procedural steps.
7. Mechanical certification requirements and completion status (e.g., certificates and
check sheets for individual tagged items in system, including civil).
8. Electrical and instrumentation certification requirements and completion status (e.g.,
certificates and check sheets for individual tagged items in system).
9. Vendor information, including:
a) Support contact information.
b) Vendor drawings.
c) Vendor data sheets.
d) FAT results and reports.
e) IRNs.
10. Preservation requirements.
11. Commissioning materials, spares, test equipment, tools, and first fill requirements.
12. Reference drawings.
13. List of drawings and documents requiring as built status and confirmation as latest
revision.
14. As built drawing markups.
15. EQs and design documents.
16. Notes and correspondence.
17. Clear definition of record filing process for certification not stored in HCP.

8.2.2. Separate system documentation


Separate document file shall be maintained for each system, including following:
a. Inspection release note (IRN)
1. IRN (GOC form IRN) is one of the most important key milestones.
2. Design and procurement process shall deliver IRN that fully complies with required
standards and specifications.
3. IRN can be simple LOC or full blown Vendor dossier for skid package that details
FAT and operating manuals for package.
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4. IRN shall confirm what has been received is exactly what was ordered, no more, no
less.
5. IRN form has various discipline checklists and disciplinary signoffs.
IRN form is available on GOC website at http://goc.bpweb.bp.com.
b. MC certificate
1. MC certificate (GOC form MC1) is a milestone in construction process.
2. MC certificate facilitates MC handover from construction authority to commissioning
authority by stating that system is mechanically complete and ready for
commissioning.
3. MC certificate shall contain description of work scope included within handover,
including exceptions as noted.
4. MC certificate shall be signed off by construction and commissioning authorities,
with discipline areas acknowledged complete as applicable and punch lists listed by
discipline entered into project punch list tracking database.
c. System handover certificate
1. System handover certificate (GOC form SH1) is a milestone in commissioning
process.
2. Certificate transfers completed system from commissioning authority to OA.
3. At this stage, commissioning activities shall be complete.
4. Certificate shall have description of work scope included in handover (with
exceptions noted) and shall be signed by commissioning authority and OA.
5. Discipline areas shall be acknowledged complete as applicable and punch lists raised
by disciplines cleared (with exceptions noted).
6. Some commissioning activities may be carried over to start up with OA approval.
d. Plant performance testing
1. Plant performance testing (GOC form PP1) is performed after system handover to
verify and validate design integrity and expectations and that facility is performing to
those expectations for agreed upon time period.
Plant performance certificate PP1 facilitates this realisation.
2. EA and commissioning authority shall confirm that plant performance tests as defined
comply with design and Vendor requirements and specifications and drawings and
that plant meets expectations of design criteria and intended purpose, if non
performance report is not entered.
e. Plant non performance
1. If non performance report (GOC form NP1) is entered, OA may accept plant
performance certificate PP1 until details of non performance or any subsequent EQs
or TQs have been satisfactorily resolved.
2. After non performance issue, EQs, and TQs, have been resolved to satisfaction of
OA, OA shall sign plant performance certificate (GOC form PP1), accepting that
plant performance tests have demonstrated design expectations have been achieved.
See clause 27 for more details.

8.2.3. System certification


a. Certificates and records shall be completed for each item in system as it is inspected,
tested, checked, calibrated, and commissioned.
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b. Certificates and records shall include:


1. Calibration, testing, and final instrument loop certification of control system
components.
2. Complete listing of calibration test equipment being used, including acceptable
tolerances.
3. Record of test equipment calibration checks performed.
4. Readout or output values from calibration.
5. For factory calibrated instruments, factory certification shall be included, and these
instruments shall be verified but not recalibrated.
6. Deficiencies as noticed and documented.
7. Concerns identified and documented.

8.2.4. Commissioning procedures


a. Commissioning procedures shall be written for each functional system.
b. Commissioning procedures shall include:
1. List of prerequisites that shall be completed before dynamic commissioning and
functional testing begins.
2. List of prerequisite systems that shall be functional to perform commissioning of
specific system.
3. List of temporary systems required to perform system commissioning.
4. Detailed set of step by step procedures for functional testing and commissioning of
system, including signoff boxes to validate each step was performed by competent
personnel.
5. List of special tools and equipment required for commissioning.

8.2.5. As built system status


a. Complete set of project drawings for each system shall be marked up to reflect as built
condition at end of project.
b. Changes to documents shall be recorded to show as built condition of document with
following colour coded format:
1. Additions shall be red.
2. Deletions shall be green.
3. Comments shall be blue or grey.

8.2.6. Engineering queries


a. Complete list of EQs created during construction and commissioning shall be maintained.
b. EQs shall be resolved and closed at time of system handover to operations.
c. Exceptions shall be documented and signed off by OA.
d. Approved management of change (MOC) tracking system (e.g., database) may be used to
track EQs instead of EQ tracking database.
e. MOC system shall comply with BP Golden Rules of Safety.

8.2.7. Punch list


a. Punch list (GOC form PL1) shall be maintained by discipline areas.
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b. Punch list shall detail outstanding work or defects relating to original work scope at point
of MC and system handover.
c. Before offering MC system handover certificate for acceptance, work content shall be
reviewed (punched) to ensure work has been constructed or installed to comply with
design routine and that plant or equipment integrity is valid or has not been impaired
during maintenance.
d. Punch list of defects found outside design or original operating capability will be normally
generated by construction and installation authority.
e. Punch list shall be accompanied by attached marked up P&IDs showing location of
defective items.
f. Other types of drawings may be added (e.g., piping isometrics, electrical SLDs). P&ID
shall remain primary drawing because it has been HAZOPed.
g. There shall be only one uniquely identified discipline specific punch list for each HCP for
each system.
h. Same punch list shall be carried forward from MC to system handover with items being
signed off or added as required.
i. Each item on punch list shall be categorised priority A or B as follows:
1. Priority A denotes major items that shall be completed or corrected before
equipment can be safely energised for commissioning or operated by introducing
hydrocarbons and before handover is acceptable.
2. Priority B denotes minor items that can be repaired, completed, or corrected at later
date, allowing equipment to be commissioned or operated without implications for
operations or safety of plant and personnel.
j. Clearing punch list items
Unless specified otherwise, responsibility for clearing punch list items shall be with
construction and maintenance authority, unless commissioning performing body or
operations have requested item be temporarily skipped to assist progress (e.g., spectacle
blind left in closed position at MC acceptance to assist commissioning leak test). This
would be cleared by turning spectacle blind to run position (open) before offering system
handover to operator for acceptance. In this particular case, item would have appeared as
B item at MC1 offer stage but as A item at system handover offer stage.
k. Punch list shall remain live and tracked until all items are completed and signed off.
l. Punch list items may be reclassified at time of system handover SH1 but only with mutual
agreement between commissioning authority and OA with migitagation plan in place.

9. Inspection, testing, and commissioning - general requirements

9.1. General
a. This GP groups tasks by construction cycle phases. Some testing and verification steps
may be combined to facilitate efficient workflow (e.g., piping hydrotesting and flushing).
b. BP personnel shall witness selected inspection, testing, and commissioning activities,
subject to BP discretion.
c. Test equipment control and calibration system shall be established to ensure that
equipment for inspection, testing, measuring, and commissioning is properly controlled
and calibrated.
d. Test and inspection equipment shall be suitable for purpose intended and regularly
maintained and serviced.
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e. Test equipment control and calibration systems shall address following, as minimum:
1. Responsibility for control and maintenance of system, including care and use of each
instrument type and performance of calibration activities.
2. Identification of instruments.
3. Calibration procedures for each type of instrument.
4. Frequency and accuracy of calibration.
5. Traceability of calibration to recognised industry or national standard or against in
house standard as applicable.
6. Records of instrument calibrations and system review.
7. Out of calibration procedure addressing both instruments overdue and those found
inaccurate.
8. Test equipment name, type, model, and last date of calibration shall be recorded with
test, inspection, or commissioning procedure being performed.

9.2. Competence
a. Personnel for inspection, testing, and commissioning shall be competent to perform
required tasks.
b. Processes shall be in place to identify and close any gaps in competence.
c. Subject to contractual constraints, Contractor shall demonstrate and document that its staff
is competent to perform assigned work.
d. Operating, design, maintenance, project, and Contractor personnel shall be trained in their
role in site procedures and in potential hazards associated with their work.
e. Periodic verification shall be performed of personnel understanding of training received
and assessment of competency.

9.3. Test dossier


a. Documentation setup
1. Comprehensive documentation system shall be established.
2. System may be created with advisory input from BP.
3. System shall be subject to BP approval before implementation.
4. Detailed or special procedures and method statements developed by Contractor or
Vendor shall be subject to BP approval before implementation.
5. Modifications or additions shall be made as necessary to cover other equipment or
systems not listed in this GP, different operating voltages or conditions, and local
statutory or other requirements.
b. Documentation contents
1. System shall include test dossier or set of test dossiers.
2. Dossier shall include specified site I&T requirements and records of actual inspection
checks and tests for installed systems, plant, and equipment.
3. Prefabrication performed off site shall be included in dossier.
c. Test certification and documentation
1. Site checks and tests shall be performed to satisfaction of inspector.

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2. Appropriate check sheets or certificates shall be completed, cross referencing them


with Vendor works tests if necessary.
3. Legible copy of each certificate (bearing original signatures) shall be preserved for
incorporation in handover volume of dossier, from which further copies may be
generated as required.
4. Contractors should use standard BP GOC certificates (highly recommended) for I&T
and commissioning such that scope is standardised and information is recorded in
same format.
5. Contractor may utilize their certificates for I&T and commissioning but only if they
contain minimum data collected as required on BPs GOC certification forms.
6. Contractor certification shall be subject to BP approval before implementation.
d. Contractor technicians
1. Qualified technicians shall be provided who are skilled in operation of required test
equipment.
2. Technicians shall perform required tests and provide necessary test data
documentation.
Certificates, inspection forms, test forms, and checksheets that fulfil test dossier
requirements are in BP GOC manual. Their use is highly recommended. GOC
certification documents are the same for western 1nd eastern editions of GOC
manuals with the exception of electrical sections, clauses 22 and 23, of this GP.

9.4. Certification of procured items


a. Certification applies to materials, plant, and equipment provided by Vendor, suppliers, and
inspection authorities in respect to material composition and properties, integrity tests, and
performance tests.
b. Receipt of items
1. Inspector shall have required certification as early as possible following receipt of
items on site and before their erection, installation, or site testing.
2. Certification packages shall be complete, and certificates shall confirm compliance
with design specification to satisfaction of inspector.
3. For packaged units, documentation for all items within that unit shall be included.
c. Certificate distribution
1. Required certificates shall be inserted in dossier provided with materials, plant, or
equipment delivered to site.
2. Dossier may be shipped separately from delivered items provided it arrives at same
time as items.
3. Inspection plan for items shall indicate to whom documents shall be sent.
d. Quarantine
1. Item received at site without required certification shall be quarantined.
2. Quarantined item shall not be issued for installation until certification is available or
inspector expressly approves release.
To facilitate certification requirements, BP GOC uses IRN. IRN is a key milestone in
GOC. Design and procurement process shall deliver IRN that fully complies with
standards and specifications. IRN may be simple LOC or full Vendor dossier for
skid package that details FAT and operating manuals for package. IRN confirms

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what has been received is exactly what was ordered - no more, no less. IRN form
has various discipline checklists and disciplinary signoffs and is on GOC website at
http://goc.bpweb.bp.com.

9.5. Inspection and test program


a. I&T program
1. Subject to BP approval, I&T program for equipment shall be prepared and submitted.
2. I&T activities shall be scheduled to smooth resource requirements as far as possible
and consistent with meeting overall program.
3. Inspector shall receive adequate notification of changes in I&T program.
4. Key I&T dates shall be highlighted for third party inspection and tests.
b. Test preparation and scheduling
1. Equipment shall be prepared for inspection and for witnessing of pre acceptance tests
in compliance with I&T program.
2. Necessary facilities and test equipment shall be provided for proper execution and
witnessing of inspections and tests.
3. I&T shall not be performed during darkness or inclement weather if these conditions
could have adverse effect on I&T, test equipment, proper witnessing, or personnel
safety.

9.6. Test equipment calibration


a. Test equipment calibration system (for both onsite and offsite testing) shall be established
to ensure that I&T equipment in Table 1 is properly controlled and calibrated.

Table 1 - Test equipment calibration

Equipment Calibration Tolerance Recommended Associated Notes


interval method standard
Pressure chart Every 90 days 1% Dead weight National Bureau
recorders tester of Standards
Thermocouples Every 90 days 5%
Temperature Every 90 days 1%
recorders
Volumeters Monthly 1%
Pressure gages Every 30 days 1% Dead weight API RP 1110 If not used
tester every 12 mo

b. System shall as minimum address following:


1. Responsibility for control and maintenance of system, including care and use of each
instrument type and performance of calibration activities.
2. Identification of instruments.
3. Calibration procedures for each instrument type.
4. Frequency and accuracy of calibration.
5. Traceability of calibration to recognised national standard or against secondary or in-
house standard, as applicable.
6. Records of instrument calibrations and system review.
7. Out of calibration procedure addressing instruments overdue for calibration and those
found inaccurate.
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c. I&T process shall ensure following:


1. Inspection equipment shall be suitable for purpose intended.
2. Inspection equipment shall be regularly maintained and serviced.
3. Project specifications or data sheets may supersede standard guidelines.
4. Inspection, measuring, or test equipment shall be calibrated as specified by BP.

9.7. Preservation and cleanliness


a. Before, during, and after erection or installation, project equipment, plant, and materials
shall be maintained to standard of cleanliness and preserved in manner appropriate to type,
duty, and climatic conditions of site as specified by project procedures.
b. Responsible engineer
1. Consideration shall be given to appointment of engineer with overall responsibility
for preservation of project equipment, plant, and materials.
2. Engineer would be responsible for preparing preservation procedures and schedules
as necessary that would incorporate Vendor recommendations.
3. Engineer would ensure that preservation procedures were followed.
c. Specific requirements for preservation of equipment and materials shall be detailed in
project specifications.
A future ETP is being considered to cover preservation requirements. BP GOC
database has preservation module that can be used to specify and maintain
preservation history for project equipment and materials.

9.8. Material identification

9.8.1. Scope and applicability


a. Methods shall be available for verifying compliance of metallic materials with
specification.
b. Verification methods are required for pressure containment equipment and fittings (e.g.,
pressure vessels, piping, valves) and for structural members used in construction of
offshore structures. Refer to GIS 36-103 for positive material identification requirements.

9.8.2. Material certification


a. Material certificates shall be checked for compliance with specification.
b. Positive tests may be needed depending on criticality of item and subjective level of
confidence in accuracy of supplied certificate.
Checking certification is particularly important if material is exotic or will be used
in sour service or low temperatures.
c. Positive tests shall be used if full traceability is specified and there is concern about
material conformance to specification.
For example, level of confidence in certificates for pipe fittings purchased from
stockists is likely to be lower than those purchased directly from reputable
manufacturer.
Absolute certainty of conformance with specification can only be obtained by
destructive mechanical testing and chemical analysis. Destructive testing can be
usefully employed on samples of relatively inexpensive items from the same batch.
High level of confidence is needed to assure that items are actually from same

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batch. This means reliance on certification and, after successful test of sample, (re-)
stamping of other batch items in presence of an authorised Inspector.

9.8.3. Test methods and equipment


For test methods and equipment for positive material identification requirements, refer to
GIS 36-103.

10. Welding and NDE

10.1. Authorities and definitions

10.1.1. General
a. Term construction shall include both onsite and offsite fabrication.
b. Construction management responsibilities and associated quality planning for welding
shall be categorised and managed as follows:
1. Onsite work
a) Construction authority shall ensure that I&T requirements are met, including
management of Contractor who provides only labour and equipment.
b) Required I&T activities to fulfil minimum quality requirements shall be clearly
defined and recorded on specific Contractor QP.
2. Offsite work
a) Construction authority shall monitor performance of Management Contractor
who is directly responsible for fabrication and I&T.
b) I&T activities to be performed by Managing Contractor that are deemed by BP
to be at critical stages in fabrication process shall be witnessed before Contractor
can proceed and clearly defined within Contractor QP.
GOC I&T summary report may also be used to detail required inspection and test
activities.

10.1.2. Welder qualifications


a. Welders or welding operators shall pass welder qualification test in accordance with
governing codes, standards, or specifications.
b. Qualification tests shall be witnessed by approved independent third party inspector,
subject to BP approval.
c. Test records shall be endorsed by authorised welding inspector whose decision on
acceptance shall be final.
If integrity of records can be demonstrated and qualifications are current, in certain
circumstances, prior qualifications of welders may be considered.

10.1.3. NDE qualifications


Qualifications and certifications for NDE personnel shall comply with ASNT-TC-1A,
AWS-QC1, or equivalent.

10.2. Weld inspection

10.2.1. General
a. Guidelines

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1. Before commencement of work, simple control system using structural fabrication or


isometric drawings for weld identification shall be implemented.
2. Drawings shall detail full weld history by identifying each weld and welder
identification symbol.
b. Material traceability may be categorised as follows:
1. Onsite fabrication
a) Secured materials storage system shall be implemented for approved auditable
suppliers, subject to BP approval.
b) Material certification and level of traceability shall be appropriate to ensure
materials meet required project codes and specifications.
2. For offsite fabrication, fabricator shall have appropriate and approved auditable
materials control system and warehousing procedures in operation, subject to BP
approval.
c. For welding and NDE operations in clauses 10.2.2 and 10.2.3:
1. Welder and welder operator performance shall be assessed to ensure that work
complies with specifications, minimum repair rate, and production milestones.
2. Welder or welding operator with consistently bad workmanship shall be subject to
retesting before being allowed to continue.
3. Decision whether welder or welding operator with questionable workmanship can be
allowed to restart welding operations is at sole discretion of welding inspector.
4. Weld examination records shall be endorsed by welding inspector to signify
acceptance of results.
5. Onsite work shall be inspected by welding inspector or delegated inspection authority
for onsite work, as designated by BP and subject to BP approval.
6. Offsite work shall be inspected by Management Contractor welding inspector or third
party inspector, as applicable, subject to BP approval.
Minimum requirements are listed but are not exclusive and may be modified and
categorised by authorised senior welding inspector or authorised welding engineer.

10.2.2. Welding
a. Before welding, welding inspector shall ensure that:
1. Procedure for cold and hot cutting and weld preparation, including material
identification transfer, has been approved by BP.
2. WPS shall be available to welder or welding operator in written form or displayed
prominently at welding location, subject to BP approval.
3. Welders and welder operators understand requirements of approved procedures.
4. Welders and welder operators are qualified to perform work.
5. System to control issue and use of welding consumables as required by project
specifications has been agreed upon by BP and is in operation.
Additional guidance on storage and control of welding consumables is in GP 18-02.
6. Appropriate measures for protection against inclement weather have been taken.
7. Welding equipment is calibrated and certified as fit for use.
8. Preheat and PWHT equipment has current calibration report and is certified for use.

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9. Weld preparations comply with WPS requirements and are clean and free of
contaminants.
10. Fit ups are within WPS tolerances.
b. During welding, welding inspector shall ensure that:
1. Relevant weld procedure as required by applicable scope of work is in place.
2. Welder or welder operator is suitably qualified.
3. Issue of consumables and their control complies with applicable WPS and control
procedure.
4. Preheat and interpass temperature levels are maintained in accordance with approved
WPS.
5. Runout tabs on critical pipe fabrication comply with applicable WPS.
6. Specified inspection hold points have been performed by appropriate NDE examiner
or welding inspector.
c. After welding, welding inspector shall:
1. Visually inspect welds to ensure compliance with WPS and good workmanship.
2. Confirm that welder identification is marked adjacent to weldment.
3. Ensure that PWHT is performed in accordance with WPS and shall endorse heat
treatment record charts accordingly.
4. Ensure that, as specified, delay before NDE for ferritic steels is enforced.
5. Verify that specified NDE inspections have been performed before or during welding
process (i.e., MT of root pass).

10.2.3. NDE
a. NDE shall be in accordance with GP 32-30 and this GP. Additional guidance on more
specific NDE methods and techniques can be found in GN 32-028.
b. NDE operations shall be monitored throughout fabrication and construction as part of
overall quality control system.
c. Before NDE, welding inspector shall ensure that:
1. NDE procedures are approved by BP.
2. NDE procedures comply with requirements of fabrication code or specification.
3. NDE operator qualifications and certifications are acceptable and are for appropriate
certification levels.
4. NDE equipment and consumables are applicable, certified, and fit for use.
5. UT equipment has current annual calibration sticker.
6. Inspection hold point areas that require crack detection to be witnessed by BP or
delegated authority have been specified.
d. After NDE, welding inspector shall ensure that:
1. For UT, DPI, or MT test has been performed using correct equipment, consumables,
and techniques and results have been reported correctly and interpreted to applicable
code.
2. RT has been performed using correct procedure and that film or other recording
media have been developed in correct manner and interpreted to applicable code.

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10.3. Certification

10.3.1. General
a. For onsite and offsite work, reporting and recording of results of inspection and NDE shall
be on approved Contractor welding completion summary reports (GOC form MW1).
b. For onsite and offsite NDE, reporting and recording of results shall be on Contractor
standard NDE forms, subject to BP approval.
One NDE report can be used for recording results of testing of more than one
acceptable weld if:
Welds are on single piping isometric or structural assembly drawing.
Parameters of testing technique are identical for each weld.
Rejectable welds and associated repairs are separately reported.
Note: This use of NDE reports does not extend to pipeline riser welds, which should
be individually reported.

10.3.2. Ultrasonic report


a. UT reports shall be used to record findings of ultrasonic inspection and techniques,
equipment, and parameters.
b. If necessary, sketch showing reportable defect area dimensions and locations or outlining
limited examination circumstances shall be attached to parent form.

10.3.3. Magnetic particle and liquid dye penetrant report


a. MT and DPI reports shall be used to record results of magnetic particle or liquid penetrant
examinations and parameters.
b. If necessary, sketch showing reportable defect area dimensions and locations or outlining
limited examination circumstances shall be attached to parent form.

10.3.4. Radiographic report


a. RT report shall be used to record results of radiographic examination of weld, equipment,
and parameters.
b. Each report shall generally cover parameters for same spool (i.e., wall thickness, diameter,
exposure time, density, radiation source type, film type, and procedure number).
c. Report may cover more than one weld.

10.3.5. Welding and bolt up completion summary


Welding and bolt up completion summary shall be used to record report numbers, including
repairs for visual examinations, NDE, and PWHT performed on each weld on subassembly or
pipe spool and bolted connections, to provide summary and allow easier retrieval of backup
certificates.
GOC form MW1 can effectively be used as acceptance document to front weld
inspection records within HCP or Contractor form, subject to BP approval.

10.3.6. Heat treatment report


a. Heat treatment report shall be used to record parameters for heat treatment of component
or weldment.
b. Welding inspector shall sign on temperature time record at beginning of heat treatment
process and sign off when process is complete.

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c. On completion of heat treatment, equipment calibration report and printout from


temperature and time recorder shall be attached to report for final acceptance.
d. If items have been post weld heat treated as batch, item numbers shall be endorsed on
original temperature time record and individual heat treatment reports (if more than one is
required) shall cross reference to heat treatment report to which original certifications are
attached.

10.3.7. Qualification test record


Following shall be on Contractor preapproved standard forms:
a. Results of monitoring weld deposits and laboratory test results.
b. WPS.
c. Welding procedure qualification record (PQR).
d. Macro survey test results.
e. Mechanical test results.

10.3.8. Welder approval test certificate


a. Welders and welding operators shall be qualified to approved WPS before work can be
performed.
b. Welder and welding operator tests shall be recorded on Contractor preapproved standard
forms.

10.3.9. Summary of approved welders


Summary of welders and welding operators (including subcontractors) shall be maintained by
welding inspector and shall fully reference welder identification, procedures, positions,
thickness, and diameters they are qualified to perform.

10.3.10. Summary of approved weld procedures


Summary of weld procedures, including qualifying positions and reports (including
subcontractors), shall be maintained by welding inspector.

10.3.11. Summary of approved NDE technicians


Summary of NDE technicians (including subcontractor) shall be fully referenced by type of
NDE and shall be maintained by welding inspector.

10.3.12. Summary of approved NDE procedures


NDE procedures (including subcontractor) shall be fully referenced on NDE procedure register
and maintained by welding inspector.

10.3.13. Weld repair register


a. Weld repair register shall be completed for each particular structural assembly,
construction isometric, or spool piece drawing.
b. Repairs, including those performed before PWHT, shall be recorded on Contractor weld
completion summary (GOC form MW1) and weld repair register.
c. Weld repairs shall be indicated as follows:
1. First repair.
2. Second repair.
3. Reweld.
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d. Indicators shall be recorded as suffix to both weld and inspection report numbers.
e. Welds that are repaired or rewelded shall retain original weld number.
f. Inspection reports for weld repairs or rewelds shall retain original report number.

11. Piping

11.1. Inspection and testing

11.1.1. Scope
a. Requirements of this clause apply to pipework within scope of GP 04-10, GP 32-30,
GP 32-40, GP 42-10 and this GP.
b. Unless specified otherwise, relevant provisions of this clause also refer to complete piping
systems of steam generating plants and power stations.
c. Crosscountry and subsea pipelines are excluded from scope of clause 11.1 because they are
structural pipework.

11.1.2. Identification and marking


a. Project shall establish single system for pipework identification to be used by fabricators
and construction sites.
b. Piping identification shall include isometric number and revision.
c. Spool pieces shall be identified by hard stamping, preferably by metallic label or low stress
dot matrix stamps on flange rim.
d. Austenitic steels and exotic materials shall not be hard stamped but may be electrically
engraved instead.

11.1.3. Inspection during prefabrication, fabrication, erection, and piping completion

11.1.3.1. General
a. Items in clauses 11.1.3.2 through 11.1.3.4 shall be verified for each line included in test
pack before flushing and hydrotesting.
b. Acceptance of offsite fabricated and onsite installed pipework shall be composite function
of clauses 10 (welding and NDE), 11 (piping) and 0 (painting, coatings, insulation). Input
by relevant discipline engineers shall be required during quality planning and subsequent
development of inspection & test summary requirements.
c. Test packs
1. Within system limits or boundaries specified, piping shall be assembled into test
packs to facilitate pressure testing (strength-testing of welds), or installation of pre
hydro tested and pre certified flanged piping, that will only need to be leak-tested or
service-tested post installation.
2. Piping test pack number shall be pre fixed with two letter ID to indicate type of test
required. Below is listed three most common piping test pack prefixes.
a) HT Hydro test (strength testing of welds); raise approved Contractor piping
completion certification (GOC form MP1).
b) LT Leak test (leak test pre certified/tested pipework); raise approved
Contractor system leak form (GOC form SL1).
c) ST Service test (service test pre certified/tested pipework); raise approved
Contractor joint integrity certificate (GOC form JI1).
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3. Contents of test packs index, as minimum, shall be as follows:


a) Work package number, and/or maintenance ID no., and test pack no.
b) Hydrotest schematic, if applicable.
c) Isometric drawings or site sketches, if applicable.
d) Flange make up tagging procedure and/or flange check register.
e) P&ID.
4. EA shall produce clear means of identifying limits of test to reflect simplicity or
complexity, as appropriate, of hydrotest scope.

11.1.3.2. Design compliance


a. Weld and NDE
1. Welding inspection and NDE shall be complete, with proper documentation in place
for traceability. See clause 10 for welding and NDE.
2. Results of welding inspection and NDE shall be on approved Contractor welding
completion summary reports (GOC form MW1).
b. Installed piping shall comply with P&IDs and piping specifications.
c. Materials shall comply with specifications, with traceability requirements in accordance
with clause 9.8.2.
d. After PWHT
1. Dimensional accuracy of spool pieces after PWHT shall be verified.
2. Spool pieces after PWHT shall be properly marked for identification.
e. Rating of forged steel fittings shall be correct.
f. Branch reinforcement shall comply with isometric and design.
g. Pipework
1. Erected pipework shall comply with design requirements, particularly with regard to
fittings, connections, slope of lines, adequacy and positioning of temporary and
permanent supports, and location of vent and drain valves.
2. For hot lines, locations and lengths of pipe shoes shall be checked to ensure that, as
lines expand on being warmed and taken into service, pipe shoes will remain on
supports.
3. Pipe shoes shall be rechecked as system warms and reaches operating temperature.
h. Valve materials shall be correct and comply with code tagging. If tags are removed,
nameplates shall be checked.
i. Required NDE, stress relieving, and heat treatment shall be performed in accordance with
specifications and properly recorded.
j. Piping welds shall comply with project specifications and appropriate qualified welding
procedures.
k. Inventory of radiographic media shall be established.

11.1.3.3. Piping, valves, and fittings


a. Relief valves and bursting discs shall be removed.
b. Control valves
1. Control valves shall be removed as required.
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2. Control valves, if included in test, may require other internal trim removed and air on
diaphragm to keep them open.
3. Flushing shall not be allowed through control valves with low noise trim.
4. Flushing through control valves shall be avoided, if practical, and shall be subject to
BP approval.
c. Automated isolation valves located at piping low points shall be removed for flushing.
d. Flange alignment
1. Flanges shall be properly aligned.
2. Correct bolts and gaskets shall be installed and properly torqued at mechanical joints.
3. Joints requiring bolt tensioning shall be properly tensioned and results shall be
recorded.
e. Lines requiring stress free installation (e.g., to pumps, compressors, vessel nozzles) shall
be checked by releasing appropriate joints such that undue stress is not applied from
incorrectly installed piping.
f. Vents and drains shall be installed, including temporary vents and drains for testing, as
required.
g. Pipe compound on threaded connections shall be as specified.
PTFE tape is not permitted on threaded connections on hydrocarbon service unless
specifically stated in installation procedure and agreed upon by BP.
Recommendations for making threaded connections are in GN 42-002.
h. Valve operating systems
1. Valve operating systems (e.g., handwheels, gear systems, control systems) shall be in
correct position relative to ball, disc, gate, or plug.
2. Spindle marking on ball, butterfly, and plug valves shall correctly reflect open or
closed position.
i. Pipe joints shall be installed correctly and to specification.
j. Instrument connections
1. Instrument connections shall be installed correctly to specification.
2. Delicate inline instrumentation shall be excluded from pressure test.
k. Orifice valve tap orientation shall be correct, and taps and plugs shall be seal welded.
l. Orifice flanges shall have required upstream and downstream clearances, and orifice plates
shall be removed after trial fitting.
m. Orifice plates (within test limits) shall be checked in accordance with control procedures.
n. Joints and linings of lined pipe shall be inspected as far as practical as erection proceeds.
o. Flange faces shall be clean and undamaged, including ring type joint (RTJ) grooves.
p. Wall thickness
1. Wall thicknesses shall be measured, as required, for compliance with specification
and for baseline data.
2. Points chosen for baseline data and subsequent periodic NDE shall be agreed upon
with inspection authority.
q. Wall thickness measurement points in externally insulated lines shall be accessible by
removable sections of insulation or jacketing or by windows.

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11.1.3.4. Ancillary equipment


a. External cleanliness of erected pipework shall be checked.
b. Inline equipment (e.g., pumps, filters, traps, strainers, check valves, globe valves, control
valves, expansion bellows) shall be installed correctly, including correct orientation for
fluid flow.
c. Instrument thermowells shall be installed.
d. Pipe supports shall be installed in accordance with drawings and schedules.
e. Temporary pipe supports installed during fabrication shall be removed, except those
required to support gas lines to be hydrotested.
f. Spring supports and hangers
1. Stop limits on spring supports shall be in position.
2. Spring hangers (including constant support type) shall comply with Vendor
recommended range of travel.
3. Travel position shall be checked after installation and again after system reaches
operating temperature.
g. Expansion joints with sliding sleeve or bellows type joint shall be adequately restrained.
h. Chain wheels and handwheel extensions to specified valves shall be installed.
i. Locking devices and interlocks to valves shall be installed.
j. Pipe penetration seals shall be installed.
k. System and all line items or equipment (e.g., exchangers, drums) shall be able to safely
withstand system line specification test pressure and weight if full of test media.
l. Lines requiring cold pull or cold spring (such as steam lines) shall have correct pullup
applied.
m. Electrical bonding or earthing (clauses 22.1.13 or 23.1.13) and cathodic protection
(clauses 22.1.19 or 23.1.19) requirements shall be met.

11.1.4. Cleaning and preliminary flushing for pressure testing


Purpose of this clause is for cleaning and preparing pipeworks for pressure testing. Procedures
for system flushing are in clause 11.2.2.

11.1.4.1. Purpose
a. Lines shall be cleared of debris (e.g. dirt, slag, and other foreign materials) by flushing
with water or blowing with steam or air, as appropriate, taking into consideration safety,
efficiency, and convenience.
b. Piping that cannot be adequately cleaned by flushing shall be cleaned by other methods
that may include dismantling and reinstallation, subject to BP approval before
implementation.
c. Flushing material and medium to be used shall be subject to BP approval before cleaning.
d. Systems to be flushed shall be checked against P&IDs to identify items that require
removal before flushing.
e. Before flushing and pressure testing, subdivision of each system into test packs shall be
agreed upon with Contractor, together with requirements for equipment isolation and
removal.
f. Systems open to atmosphere, which do not require flushing, shall be blown down to ensure
lines are not restricted.
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g. Additional pretest requirements from asset specific and design house or engineering
support or BP specifications and international standards, such ASME B31.3, may be
considered and referenced over and above other requirements.
h. Pipe sections or systems that are short in length with pipe diameters sufficiently large may
be visually inspected in lieu of flushing.
i. Combination of flushing and visual inspection may be accepted and indicated on system
flush certificate.

11.1.4.2. System preparation for flushing and pressure testing


a. Equipment removal
1. Positive displacement meters (and their strainers), turbine meters, bursting discs, flow
nozzles, orifice plates, level gages, pressure gages and safety and pressure relief
valves shall be removed or blanked off before flushing and testing.
2. To avoid straining piping, temporary spacers or spool pieces shall be fitted to
complete pipework.
3. Temporary spool pieces shall be same internal diameter as piping.
4. Temporary fittings shall comply with specification of system being tested and be
clearly identified for later removal.
5. Impulse piping to instruments shall be disconnected from instrument downstream of
first block valve during flushing and testing of main process lines.
6. Analyser sampling systems shall be disconnected.
b. Speciality items and fittings, if removed, shall be wrapped in protective material and
securely tied to location.
c. Inline service strainers shall be removed before flushing and replaced after flushing is
complete.
d. Temporary strainers and filters
1. Operator advice and agreement shall be obtained on mesh size, type, and location of
temporary strainers and filters.
2. Record of temporary devices shall be kept to ensure they can be accounted for after
removal.
3. Devices shall have tabs that project at least 75 mm (3 in) beyond retaining flanges
such that they can be readily seen.
e. Control valves
1. Control valves and softseated valves shall be removed before flushing.
2. If removal of valves is not possible, internal fittings shall be removed but only after
BP approval.
3. Flushing is not permitted through control valves with low noise trim.
4. If items are removed, temporary spool pieces shall be fitted to complete pipework to
avoid straining piping.
5. Temporary spool pieces shall have same internal diameter as piping.
6. Temporary fittings shall comply with specification of system being tested and be
clearly identified for later removal.
f. Sprinkler piping
1. Sprinkler piping shall be flushed and then plugged for pressure testing.
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2. Heads, rosettes, and nozzles shall be fitted after pressure testing.


g. Pipe supports
1. Pipe supports and anchors shall be fitted before flushing and pressure testing.
2. Temporary supports required during fabrication and erection shall be removed.
3. In certain cases, additional pipework supports may be required due to weight of
flush/testing medium.
4. Design, position, and loadings for both temporary supports and pipework and their
foundations shall be subject to BP approval.
h. Expansion joints of sliding sleeve or bellows type and spring hangers shall have temporary
restraints to limit lateral movement.
i. System being pneumatically tested shall have tested safety valve of adequate capacity that
is set to relieve at 10% over test pressure.
j. Joints
1. Joints, including butt welds and welded attachments, shall be free of paint, dirt,
grease, and temporary protective coating.
2. Joints shall be left uninsulated for pressure testing.
3. Requirements in 1. and 2. may be waived at inspector discretion, except for closing
welds and joints in respect to prefabricated sections that were previously pressure
tested.
4. After testing, field welds shall be coated in accordance with relevant specification.
k. Battery limits and offtakes shall be isolated by blinding or locked closed valves and
hazardous warning signs shall be posted.
l. Temporary blinds, spectacle blinds, or orifice plates that are installed, turned, or removed
shall be entered in respective registers.

11.1.4.3. Flushing and test preparation specifics


a. Lines shall be flushed to low point in system.
b. If control valve location is used as flushing out point, entire control valve shall be removed
before flushing.
c. Flushing shall not be performed through machinery or equipment that may be damaged by
flushing.
d. Flushing with equipment, vessels, and tanks online is permitted if pressure and weight of
flushing medium can be tolerated and any internal instruments, fittings, or other devices
that would be subject to damage have been removed.
e. Debris shall not be flushed into vessels, equipment, or dead ends.
f. Separators, heat exchangers, and similar vessels may be used as paths for flushing but
upstream piping shall have suitable metallic permanent or temporary strainers or lines shall
be flushed with equipment isolated.
g. High points shall have vents to expel air.
h. Low points shall have drains.
i. Air or steam blowing
1. If air or steam blowing is used, special precautions regarding exhaust area and thrust
on pipework shall be considered and identified.

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2. Special attention shall be paid to ensure that electrical, electronic, or other equipment
adjacent to or below exhaust is not deluged.
j. Chemical cleaning
1. Chemical cleaning of systems (e.g., machinery seal oil or lubrication oil systems) may
be specified in some cases.
2. In these cases, special procedures shall be subject to BP approval.
k. Inline valves
1. Inline valves shall be in fully open position during pressure test.
2. Pressure tests shall not be made against closed block valves.
3. Blinds shall be used with valves open.
4. Check valves shall have either disc removed or be jacked open for flushing and
pressure testing.
5. Every effort shall be made to remove wafer type check valves.
6. If removal of wafer type check valves is not possible, internal flap shall be removed
(not tied back).
7. On reinstatement, internals of valves shall be checked for cleanliness and damage.
l. Some inline valves, notably ball valves, shall be tested with valve half open to ensure that
seals are not exposed to excessive differential pressure and to allow valve stem and body to
be pressure tested.
m. Vessels and heat exchangers
1. Vessels and heat exchangers in piping systems may be tested as whole, unless vessel
test pressure is less than specified for piping.
2. Vessels and heat exchangers shall only be included in system pressure test if item has
previously been pressure tested in accordance with code requirements to test pressure
at least equal to piping system test pressure.
3. Inspector shall verify that manufacturer or site pressure test certificates are available
onsite for vessels and heat exchangers before approval is given for inclusion of such
items in system test.
n. Test media
1. Checks shall be performed to ensure that system and line items can safely withstand
specified system flushing pressure and weight if full of water or other test medium.
2. Particular attention shall be given to possibility and prevention of overstressing
tubesheets that were designed on differential pressure basis.
3. If vessels so designed cannot support full head of water or if foundations or
supporting structures impose weight limit, vessel may be included in flush by
partially filling with water and introducing air or nitrogen blanket.
4. Detailed procedure for such flushing (including safety precautions to be taken) shall
be prepared by Contractor, subject to BP specialist vessel engineer approval.
5. Means shall be provided to prevent flushing pressure from being exceeded.
a) Recommended approach shall be to install relief valve to protect vessel during
flushing of adequate capacity set at 10% above test pressure on fluid supply
system.
b) Safety valve shall be capable of discharging capacity of the charging system at
test pressure.
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o. If relief valve from vessel is used for this purpose, spring having correct pressure range
shall be fitted for test period. After testing, relief valve shall be reconfigured with original
spring and recalibrated to original set pressure, tested and reinstalled.
p. Spring hangers and supports
1. After system is filled for testing, spring hangers and supports shall be checked and
reset.
2. Spring hangers shall be blocked if testing steam or gas lines with liquid.
q. Flush rates
1. Flush rates shall be high enough to remove heavy debris.
2. If flushing medium is water, flow velocities shall be 1,5 to 2 times normal operating
velocity or 3 m/s to 4 m/s (10 ft/s to 13 ft/s), whichever is greater, if possible.
r. Water flushing medium
1. Flushing shall be performed with clean fresh water, potable water, or treated
seawater, as appropriate.
2. For systems containing austenitic stainless steel piping and fittings, chloride ion
content of water shall be less than 50 ppm.
3. Carbon steel pipework flushed with sea water shall be dried immediately after
flushing to prevent corrosion.
Additional guidance on treatment of hydrotest water is in GP 06-29.
s. Air or steam flushing medium
1. If flushing medium is air (oil free and dry) or steam, flow velocity shall not be less
than 20 m/s (65 ft/s).
2. Records of flushing shall be maintained by colour marking P&ID to define system
flushing circuits, direction of flow, scope, equipment isolation, and prime mover
used.
t. Flushing or blowing shall continue until required cleanliness of system is attained.
u. Flushing outlets
1. Flushing outlet connections shall have basket for trapping debris.
2. Precautions shall be taken to ensure water is safely drained away while flushing.
3. Deflectors shall be provided, if necessary, to prevent refuse from entering open
equipment.
4. Flush shall be to open end, if possible.
5. Flexible hose or pipe, if required to route medium away, shall be at least same
diameter as piping.
6. Area of flush discharge shall be cordoned off and hazardous warning signs posted.
v. Flushing shall be performed through every dead leg equipped with drain valve to remove
debris.
w. Flushing of interconnecting piping shall be in direction of fall (high to low) and from
smaller piping to larger to ensure no debris is left trapped in dead legs.
x. Construction Authority shall sign off relevant section on approved Contractor piping
completion certificate (GOC form MP1) upon satisfactory completion of flushing and
cleaning.

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y. On reinstatement, system shall be checked against P&ID, blinding and orifice register, and
then master P&ID shall be updated.

11.1.5. Pressure testing

11.1.5.1. Purpose
Pressure testing (strength testing of welds) shall be used to verify integrity of piping and
equipment as a result of new construction, modification, or repair.

11.1.5.2. Safety
Hazards involved in pressure test shall be carefully considered by all parties concerned. Before
such testing is conducted, method and safety precautions shall be documented, reviewed, and
approved by competent person. Further information on pressure testing can be found in
GP 32-40.
Stored energy and its rapid release in the event of failure is major hazard related to
pressure testing. The preferred test media is water or other nominally inert and
incompressible fluid. Stored energy is of significant concern when any of the
following conditions apply:
High test pressures where compressibility of water becomes significant issue.
If the material of fabrication (e.g. glass reinforced plastic) can store and release
energy at high rate.
Significant volumes of air or compressible gas remain in the system to be tested.
A particular concern for large complex systems (e.g. pipelines).
A compressible fluid is being used as the test media (e.g. air, nitrogen).
If stored energy contained within equipment or test fluid is high, precautions shall be taken to
minimize consequence of failure.
a. For audible or visual techniques, test pressure should be limited to 110% of maximum
operating load or pressure and,
b. When practicable, pressure systems should be subdivided into smaller test sections to
minimise the stored energy in each test.
Guidance on the calculation of stored energy and precautions to be taken can be
found in GP 32-40.
c. When performing tests, consideration shall be given to:
1. Determining as far as practicable that equipment is free from defects that are outside
acceptance criteria.
2. Protection of ancillary equipment.
a) Isolation of relief valves, overload alarms, and trips shall be strictly controlled
and recorded.
b) Control valves and other equipment shall be protected from over pressure during
test.
3. Restricting access to the test. Additional precautions shall be considered when the
testing media is other than water (environmental, flammability, toxicity,
compressibility).
Water should not be considered non-compressible fluid and stored energy during
hydrostatic testing, especially at very high pressures, should be considered.
4. Ensuring equipment under test is protected from all forms of shock load including
hammer testing.

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5. Ensuring precautions are in place to prevent exceeding the maximum test load.
6. Ensuring the testing equipment has maximum safe working load at least equivalent to
the maximum test load.
7. Repeated overload of equipment, ensuring that test equipment is not repeatedly
overloaded due to being used for repetitive tests.
8. Ensuring that risk of catastrophic failure, e.g. brittle fracture at reduced test
temperature, is addressed.

11.1.5.3. Hydrostatic testing


a. Pressure testing may proceed after flushing is satisfactorily completed.
b. Test specifications
1. Testing shall be performed in accordance with requirements specified on line test and
piping line specification or otherwise shall take into account duty of system,
specifically process fluid and operating pressures and temperatures.
Before filling system with fluid, it may be prudent to perform low pressure air test
under controlled conditions to ensure there are no major leaks. ASME B31.3 limits
preliminary test pressure to 1,7 bar ga (25 psig).
2. Vessels and/or heat exchangers may be incorporated as part of pressure test of piping
system only if vessel and/or heat exchanger test pressure is less than that specified for
piping test.
3. Hydrostatic test requirements shown on isometric, P&ID, line list, and general
arrangement drawings shall be compatible with applicable codes and specifications.
4. Test pressure shall comply with code to which piping was designed.
5. If possible, test limits shall be defined to coincide with system completion and leak
test requirements.
6. Test duration shall be at least 30 minutes from when inspector agrees that test
pressure has been attained.
Design of piping systems for BP is generally based on requirements of ASME B31.3,
which details parameters for hydrostatic testing, such as 1,5 times MAWP, with
variations to be considered as detailed in ASME B31.3. At some sites, minimum test
pressure applied is not normally less than 6,9 bar ga (100 psig).
c. Valve settings
1. Inline valves shall be in fully open position during pressure test.
2. Pressure tests shall not be made against closed block valves.
3. Blinds shall be used with valves in open position.
4. Non return valves shall either have disc removed or jacket open for pressure testing.
5. Some inline valves, notably ball valves, shall be tested with valve in half open
position to ensure seals are not exposed to excessive differential pressure and to allow
valve stem and body to be pressure tested.
d. Test medium
1. Test medium may be clean fresh water (preferred option), potable water, 60/40
water/glycol treated inhibited sea water, oils, air, or inert gases.
2. For austenitic stainless steel piping, chloride ion content of water shall not exceed
50 ppm.

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3. Flammable liquids used for testing shall have flash point above 65C (149F).
Hydraulic oil and instrument air systems are typically only tested using specified
operating medium.
Choice of test medium and type of test may be constrained by:
Availability of fresh water (sea or brackish water may need to be inhibited).
Deleterious effect of certain test media on piping material (e.g., chloride ion on
austenitic steels) or on operating fluid (e.g., water contamination of hydraulic
oils or instrument air or danger of moisture in acid, ammonia, liquefied gas, and
catalyst services).
Pipework configuration that may preclude adequate draining and require
pneumatic test. See clause 11.1.5.4.
Cold ambient conditions that may require antifreeze additives or use of kerosene
or gas oil.
e. Test temperatures
1. Attention shall be paid to effects of high or low ambient temperatures occurring
during test.
2. Temperature of material under test, if tested below 15C (60F), shall be safely above
that at which brittle fracture of notch sensitive ferritic steels may be initiated.
Specialist advice shall be sought if in doubt.
3. If necessary to conduct test while ambient temperatures are below or likely to be
below 5C (35F), use of antifreeze solution or alternate testing media, such as gas oil
or kerosene, shall be subject to BP approval.
4. Specialist vessel and piping engineer shall be consulted regarding pressurising
systems and vessels at temperatures below 0C (32F) before BP approval.
5. Separate test procedure outlining storage, recovery, and disposal of alternative test
medium shall be subject to BP approval.
f. Test equipment
1. Test equipment used to apply test pressure shall have safe working pressure at least
equivalent to maximum test pressure.
2. Equipment used for test pressure measurement shall be calibrated throughout range
against known standard.
g. Test gages
1. Calibrated test gages of suitable pressure indication range shall be installed at high,
low, and entry locations.
2. Individual isolation valves shall be in open position.
3. Gage at highest point shall indicate required test pressure.
4. Pressure and temperature recorders and dead weights shall be used on all hydrostatic
tests for ASME B31.3, ASME B31.4, ASME B31.8, and API 1104 piping systems.
5. Test gages shall:
a) Have individual reference number.
b) Be calibrated on regular basis.
c) Have calibration record maintained.
h. Vents and other high point connections that can serve as vents shall be open during filling
such that air is vented before pressurisation.
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i. Piping designed for vapour or gas shall have additional temporary support as necessary to
support test liquid weight.
j. If test system is filled with test medium and construction authority is satisfied that air
pockets have been removed, pressure shall be gradually increased to required test pressure.
k. Continuous attendance and supervision shall be maintained at test pump while test system
is pressurised.
l. Pressure gages shall be monitored at all times during test.
m. Hydrostatic head on gage shall be taken into account depending on gage location.
n. Test pump shall be physically disconnected from test system after test pressure is reached.
o. Test pressure shall be held at least 30 minutes before detailed inspection begins.
p. Inspection
1. System under test shall be visually inspected over entire length by construction
authority.
2. Each mechanical, welded joint, attachment, and other connection shall be checked.
3. Test duration shall be at least 30 minutes or time taken to inspect system, whichever
is greater.
4. If visual inspection over entire length of system is not possible (e.g., partially buried
or underground sections), then 24 hour holding test shall be performed utilising dead
weight chart recorder type to record both pressure and simultaneous temperature over
test period.
This type of holding test should be avoided if possible and preference given to visual
inspection of system.
q. If leaks are discovered:
1. Necessary repairs or replacements shall be made.
2. Test shall be repeated.
3. Construction authority shall be notified that retested items have passed test.
r. Post test activities
1. After satisfactory completion of pressure test, construction authority shall witness
gradual release of pressure and drain down.
2. Test system shall be depressurised by opening depressurising valve in test rig.
3. Test system shall be drained by opening all vents and low point drain valves.
4. Adequate venting shall be used to avoid vacuum conditions.
5. Drained lines shall be dried by purging with oil free dry air.
s. Pipeline pigging and gaging
1. Pipeline pigging and gaging shall be performed in accordance GP 43-50.
2. Construction authority shall verify pipeline dewatering and inspect and approve gage
plate condition.
t. Test completion
1. Lines shall be pressure tested.
2. Test shall be witnessed by inspector.
u. Certification of hydrostatic testing

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To record that inspection and test requirements of clause 11.1.5 for flushing, cleaning, and
hydrostatic testing have been performed satisfactorily and that checks and documentation
are complete, construction/maintenance authority shall complete following on approved
Contractor form:
1. Piping completion certificate (GOC form MP1).
2. Piping completion certificate shall be used for:
a) Recording that piping has been satisfactorily pressure (strength) tested and
reinstated before system leak testing and placed in service.
b) Flushing/blowing has been carried out to required cleanliness.
c) Associated pressure, temperature, and time records shall be attached to piping
completion certificate (GOC form MP1).
d) Piping has been satisfactorily reinstated in accordance to clause 11.1.10.

11.1.5.4. Pneumatic testing


a. Pneumatic testing shall only be performed as specified and approved by BP.
b. Pneumatic testing shall only be performed if agreed upon in writing with:
1. For onsite, OA.
2. For offsite, BP or delegated authority.
c. Vessels and/or heat exchangers may be incorporated as part of pressure test of piping
system only if vessel and/or heat exchanger test pressure is less than that specified for
piping test.
d. Pneumatic testing pressures greater than 6,9 bar ga (100 psig) shall be avoided.
e. System being pneumatically tested shall have tested safety valve of adequate capacity that
is set to relieve at 10% over test pressure.
f. Construction authority shall be in charge of activities associated with pneumatic testing.
g. Unless approved by BP, testing shall not be performed at ambient temperatures below
15C (60F).
h. Air for purging and testing shall be clean, dry, and oil free.
i. Access to test area
1. Access to pneumatic test areas shall be restricted solely to those persons required to
conduct test.
2. Barriers shall be installed to prevent access to others.
j. Test pressures shall be 1,1 times MAWP.
k. Before pneumatic test begins:
1. Butt welds shall be 100% radiographed.
2. Socket welds shall be visually inspected for surface cracking.
l. Preliminary check shall be made at not more than 0,7 bar ga (10 psig).
m. Test solution
1. Test solution shall consist of simple mixture of liquid detergent and water.
2. Test solution shall be prepared not more than 24 hour before test.
3. Bubble formation properties of solution shall be checked throughout test period.
n. Test procedure
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1. System shall be gradually pressurised to 60% of specified test pressure and held at
this pressure for sufficient length of time (minimum of 10 minutes) to allow piping to
equalise strains.
2. Pressure shall then be reduced to 50% of specified test pressure and joints shall be
retested for leaks.
3. Pressure shall be raised in steps of not more than 10% until specified test pressure has
been reached.
4. Pressure shall be held at each step during pressurising sequence to allow piping to
equalise strains for at least 10 minutes.
5. Specified test pressure shall be held for sufficient length of time to permit inspection
of joints, but under no circumstances less than 30 minutes.
6. After system is at test pressure, leak test solution (e.g., soapy water) shall be applied
completely around connections, welded joints, packing, and glands to detect any
leaks.
7. While system is under test pressure, test equipment shall be positively isolated from
system.
8. Flanged joints shall be completely taped and small holes punched at top or side to
detect leaks.
o. If leaks are discovered, system shall be:
1. Depressurised and leaks repaired.
2. Retested to specific test pressure.
p. Test completion
1. Lines shall be pressure tested.
2. Test shall be witnessed by inspector.
q. Certification of pneumatic testing
To record that inspection and test requirements of clause 11.1.5 for flushing, cleaning, and
pneumatic testing have been performed satisfactorily and that checks and documentation
are complete, construction/maintenance authority shall complete following on approved
Contractor form:
1. Piping completion certificate (GOC form MP1).
2. Piping completion certificate shall be used for:
a) Recording that piping has been satisfactorily pressure (strength) tested and
reinstated before system leak testing and placed in service.
b) Flushing/blowing has been carried out to required cleanliness.
c) Associated pressure, temperature, and time records shall be attached to piping
completion certificate (GOC form MP1).
d) Piping has been satisfactorily reinstated in accordance to clause 11.1.10.

11.1.5.5. Fire and gas safety systems


a. Piping associated with firewater mains, fire suppression systems, sprinkler systems, and
deluge systems shall have following test performed to ensure return of piping under
pressure test to state of MC:
1. As soon as possible after completion, firewater system shall be charged at full
capacity, subject to BP approval of charging procedure.

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2. Valves and equipment shall be operated to test facility under flowing conditions.
3. Special certification or regulatory agencies (especially for offshore) may be required
to witness test.
4. Sprinkler heads, sprinkler rosettes, and sprinkler nozzles shall be correctly installed.
5. Hose couplings shall be correctly installed.
6. Discharge heads on non Halon fire suppression systems shall be correctly installed.
7. Following shall be correctly installed:
a) Fire hydrants and monitors.
b) Foam monitors.
c) Non Halon fire suppression cylinder locations and fixings.
Halon as fire suppressant is being phased out by BP to comply with EPA regulations
1996 S.I. 506.
b. Test completion
F&G as test shall be witnessed by inspector.
c. Certification of F & G safety system
To record that inspection and test requirements of clause 11.1.5 for flushing, cleaning and
testing of F & G safety systems have been performed satisfactorily and that checks and
documentation are complete, construction/maintenance authority shall complete following
on approved Contractor form:
1. Piping completion certificate (GOC form MP1).
2. Piping completion certificate shall be used for recording that:
a) Piping has been satisfactorily pressure (strength) tested and reinstated before
system leak testing and placed in service.
b) Flushing/blowing has been carried out to required cleanliness.
c) Associated pressure, temperature, and time records shall be attached to piping
completion certificate (GOC form MP1).
d) Piping has been satisfactorily reinstated in accordance to clause 11.1.10.

11.1.6. Mechanical joint integrity


a. Purpose of joint integrity installation procedure is to provide process by which risk
potential piping is identified and recorded.
b. This clause contains two parts: high risk and low risk potential piping.
Details are covered in piping joints handbook GN 42-002.
c. High risk potential piping
1. High risk potential piping may consist of following:
a) Process hydrocarbon.
b) Diesel.
c) Process chemicals.
d) Hydraulic fluids.
e) Lubricant oil systems.
f) Water injection.
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g) Produced water reinjection.


2. Piping that facility deems high risk potential shall be subject to joint integrity install
procedure as outlined.
3. Joint integrity certificate shall be used to record and formalise installation, making
and remaking of flanges, joints, compression fittings, and plugs in ported blanks on
critical duties as specified by commissioning authority or OA.
4. Such joints shall be checked and signed in on joint integrity certificate by
commissioning and operations representative.
5. Such pipework shall be subject to leak testing, service testing, and pre and post
system handover.
6. Three point check shall ensure integrity of joint with data collected during
construction and installation phase, commissioning phase, and operational phase.
7. Construction and installation phase (GOC form JI1 Part A) shall include:
a) Joint or flange assigned tag number.
b) Location of joint noted on P&ID.
c) Date of joint install and by whom.
d) Data shall be completed by construction authority and installation authority.
8. Commissioning phase (GOC form JI1 Part B) shall include:
a) Who leak tested joint.
b) Leak test number.
c) Data shall be completed by commissioning authority.
9. Operational phase (post system handover) (GOC form JI1 Part C) shall include:
a) Who witnessed service tests over period of 72 hour during warmup and startup.
b) Data shall be completed by OA.
GOC form JI1 parts A and B needs to be completed and signed before system
handover acceptance.
GOC Manual has joint integrity certificate (GOC form JI1) to record that post
system handover (SH1) startup and warmup service tests have been performed, that
each joint has been subject to one service test at startup and warmup and one
service test every 12 hours thereafter for 7 days has been performed.
10. Procedure shall also be followed for maintenance activities if containment is broken
or in absence of approved flange or joint tagging procedure for construction activities
during projects or modifications.
11. If construction authority has procedure that meets requirements and intent of this
clause, construction authority procedure shall be reviewed for use, subject to BP
approval.
12. Tag numbers
a) Each tag shall have unique identification number.
b) Supply of flange and joint tags shall be readily available at locations on facility
(e.g., control room, instrument, and mechanical workshops).
13. Flanges, joints, compression fittings, and plugs in blank flanges shall be tagged if
installed or reinstalled following maintenance for piping containing, but not limited
to:

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a) Process hydrocarbons.
b) Diesel.
c) Process chemicals.
d) Hydraulic fluids.
e) Lubrication oil systems.
f) Water injection.
g) Produced water reinjection.
14. Person who makes or breaks pipework joint integrity shall mark up tag numbers on:
a) Copy of relevant P&ID.
b) Corresponding joint integrity certificate (GOC form JI1).
15. After pipework is made up, authorised and competent pipe fitter or technician
performing task shall sign and date appropriate box on joint integrity certificate (GOC
form JI1 Part A).
16. To demonstrate joint integrity has been achieved and maintained, marked up P&ID
highlighting test limits and joint integrity certificate shall form part of HCP.
17. On completion of successful leak test or service test, approved Contractor system leak
certificate (GOC form SL1) and joint integrity certificate (GOC form JI1 Part B) shall
be signed by competent person performing test.
18. If piping is new or disturbed and if post system handover startup and warmup service
testing is applicable, before tags are removed, each joint shall be monitored after
equipment has been brought into or returned to service and shall be subject to:
a) Service test at startup.
b) Service test at warmup.
c) Service test every 12 hours thereafter for 7 days after warmup service test date.
19. During monitoring period, tagged piping shall be inspected and results shall be
recorded on approved Contractor joint integrity certificate (GOC form JI1 Part C).
20. Tags removal shall be recorded on joint integrity certificate and tags collected and
returned to OA.
21. Multiple items on one tag
a) If several new joints or breakages of containment are localised, one tag may be
used to control items (e.g., number of instrument tappings around pump on lube
oil skid).
b) In these cases, provisions of leak testing monitoring and recording are still
required.
c) Break points shall be marked with unique identification number (e.g., 1666A,
1666B) on P&ID or other drawing.
22. Joint register
If multiple joint integrity certificates are utilised, it may be necessary to create joint
register for tracking purposes.
d. Low risk potential piping
1. Piping with low risk potential may contain:
a) Seawater.

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b) Firewater.
c) Plant air.
d) Instrument air.
e) Domestic waste.
f) Potable water.
g) Municipal water.
h) Industrial water.
2. Low risk potential piping may not be subject to flange or joint tagging procedure or
system leak test.
3. Quality of work is still important on low risk systems and shall be subject to
inspection and service testing as appropriate to ensure TI has been achieved and
maintained.
4. Systems with operating pressure above 6,9 bar ga (100 psig) for water or 1 bar ga
(15 psig) for air shall have:
a) Service test.
b) Joint integrity certificate (GOC form JI1) entered.
5. If operating pressure is below 6,9 bar ga (100 psig) for water or 1 bar ga (15 psig) for
air:
a) No formal testing or certification is required.
b) If applied to maintenance activities, activity shall be recorded in maintenance
management system.
c) If applied to projects or modifications, activity shall be recorded on MC
certificate (GOC form MC1) and system handover certificate (GOC form SH1).
6. If plugs are removed from instrumentation or piping for maintenance or if
hydrocarbon system containment is broken (e.g., if sampling or blowing down
instruments), there is no requirement for formal joint integrity certification process if:
a) Work is performed by competent and authorised person.
b) Original compression fittings are remade.
c) Service test is performed by technician performing work.
d) Tasks, including service test, are completed within one shift.
7. To demonstrate that joint integrity have been achieved and maintained, marked up
P&ID that highlights test limits and joint integrity certificate, if required, shall form
part of HCP.
8. On completion of successful leak test or service test, system leak certificate (GOC
form SL1) and joint integrity certificate (GOC form JI1) shall be signed by competent
person performing test.
9. If low risk piping is recorded on GOC joint integrity certificate JI1, columns that are
not applicable, such as tag number, joint installed by, date of installation, leak tested
by, and SL1 leak test number, shall be marked N/A.
Joint integrity certificate JI1 records that post system handover startup and warmup
service tests, as appropriate, have been performed.

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11.1.7. Critical joint installation


a. Critical joint is defined as witnessed joint installation in which following conditions can
exist:
1. Located in high risk system.
2. Requires witnessing of proper flange makeup. Refer to c.3. through c.9.
b. Such joints are normally on pipes carrying hydrocarbons that are not subject to pressure or
leak test.
c. In conjunction with joint integrity procedure in clause 11.1.6, following shall be
implemented for preparation, pulling up, and tightening of certain flanged joints on critical
duties if specified by commissioning authority or OA:
1. Commissioning authority or OA shall be advised before joint installation to enable
assessment for requirement to witness joint installation.
2. Flange faces shall be clean and damage free.
3. Gasket shall be new, damage free, and of correct specification and size.
4. Nuts and stud bolts shall be damage free and of correct specification (material) and
size.
5. Flange faces shall be parallel and aligned in accordance with specification.
6. Joint shall be progressively tensioned evenly using crisscross bolt tightening sequence
in accordance with BP specification[JRF1].[MKM2]
For[JRF3] additional information on bolt tightening, refer to GP 46-01, Annex Q.
7. Nut tightening
a) Nuts shall be pulled up to required torque tightness.
b) Minimum of one thread shall protrude through each nut.
c) No excessive length of stud bolt shall protrude through each nut.
8. There shall be no visible damage to gasket as joint is compressed.
9. To demonstrate joint integrity has been achieved and maintained, markup P&ID
indicating appropriate joints and completed pertinent section of joint integrity
certificate (GOC form JI1, Part B) shall form part of HCP.

11.1.8. Prefabricated pipework


a. Fully prefabricated pipework, complete with flanged ends, will not normally require repeat
test at full hydrostatic test pressure if following conditions apply:
1. Hydrostatic strength test has been performed at Vendor works.
2. Approved test certificate along with pressure and temperature recording chart is
available to cover test.
3. There is no regulatory requirement for repeat site pressure test.
b. Final leak test to check for joint tightness is required in all cases (see clause 11.2.3).
c. Test certificate in clause 11.1.5.3 shall have line numbers recorded.
d. Suitable identification marks shall be stamped on flanges or otherwise tagged on piping.
e. Inspector shall consider imposing requirement that tightening of flanged joints not subject
to system pressure test shall be witnessed.
This is particularly important for lines in critical service or if operating pressures
exceed 20,5 bar ga (300 psig).
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11.1.9. Closure welds


Tests on closing welds in lines that have previously been tested in sections or retests due to cut
in to line that has already been tested may be waived at inspector discretion if following
conditions are satisfied and results are to inspector satisfaction:
a. Preparation and welding are performed under inspector supervision.
b. Full (100%) radiography is performed on closure welds.
c. Other NDE requirements imposed by inspector and approved by EA are met.
These non pressure tested closure welds are sometimes referred to as golden
welds.

11.1.10. Post test reinstatement and completion


On each line, following checks shall be performed by construction authority representative to
ensure satisfactory reinstatement of piping under test:
a. On completion of pressure testing, piping and any vessels or equipment included in test
shall be vented, drained, and, if necessary, cleaned and dried by blowing through with oil
free compressed air to satisfaction of inspector.
If water was used to test systems in which moisture cannot be tolerated, special
drying techniques may have to be employed (e.g., use of hot dry air). Special
attention should be paid to places where water may be trapped, such as valve
bodies, low points, and dead ends. Use of water in such situations can only be
permitted in extreme cases because another medium is not available.
b. Temporary equipment
1. Spades, blanks, temporary strainers, and any other equipment installed for testing,
shall be removed on completion of testing.
2. Permanent strainers shall be opened and cleaned.
3. If flanged joint is broken, joint rings or gaskets shall be renewed.
4. Inspector shall witness remaking of joints in critical and high pressure service.
5. Temporary bolting shall be replaced to satisfaction of inspector.
6. Temporary fitments installed to limit travel (e.g., in expansion joints and pipe
hangers) shall be removed.
7. Hangers shall be checked and reset as necessary.
c. If necessary, valves shall be repacked with appropriate grade of material.
d. Construction joint integrity register and flange checklist register shall be completed as
applicable.
e. Piping shall be installed or reinstated and flushing and hydrostatic testing shall be
satisfactorily completed and recorded.
f. Flange alignment shall be correct.
g. Bolts and gaskets
1. Bolts and gaskets shall be correctly installed at mechanical joints.
2. Bolts shall be set to correct torque setting.
3. Bolts shall be lubricated.
4. Joints requiring bolt tensioning shall be correctly set using bolt tensioning procedure
and results shall be recorded.

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h. Compound on threaded connections shall be as specified. Note that use of PTFE tape on
threaded connections on hydrocarbon service is not permitted unless specifically stated in
installation procedure and agreed upon by BP.
i. Vents and drains shall be correctly installed with plugs or blind flanges.
j. Temporary vents and drains shall be plugged off and seal welded as applicable.
k. Process blinds and spacers shall be correctly installed as indicated on P&IDs.
l. Spectacle blinds shall be in correct (open or closed) position.
m. Pipe cleaning and pickling shall be satisfactorily completed in accordance with project
specifications and results recorded.
n. Control valves shall be installed in correct flow direction.
o. Specified block valves shall have locking devices correctly installed.
p. Valves shall be:
1. Functioning properly.
2. Correctly lubricated.
3. Installed in correct flow direction.
q. Temporary pipe spools shall be removed and control valves and internals shall be
reinstated in correct flow position.
r. Non return valves
1. Non return valve internals shall be reinstated.
2. Valve shall be installed in correct flow direction.
3. Jack open devices shall be removed.
4. Valve shall be functioning properly and spindles shall be lubricated.
s. Relief valves and rupture (bursting) discs shall be correctly installed.
t. Instrument gages shall be correctly installed.
u. Pump suction strainers shall be correctly installed and temporary test strainers shall be
removed.
v. Speciality items (e.g., steam traps, small inline strainers, expansion joints, spring supports,
hangers) shall be correctly installed.
w. Valve tags shall be correctly installed.
x. Chain wheels, chain wheel safety cables, and handwheel extensions to specified valves
shall be correctly installed.
y. Locking devices and interlocks to valves shall be correctly installed.
z. Pipes and supports shall be properly installed.
aa. Blinds and line spacers shall be rated equal to or greater than line class to be tested.
bb. Flowmeters shall be installed in correct flow direction.
cc. Orifice plates on flow meter runs shall be installed in correct flow direction with orifice
opening in correct position in pipe cross section.
dd. ROs shall be correctly tagged and installed with correct size orifice opening and piping
specification.
ee. Upon completion of checks for reinstatement of piping after testing:

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1. Joint integrity procedure and flange checklist register shall be properly updated as
applicable.
2. Appropriate joints shall be tagged and relevant tag ID shall be detailed on appropriate
drawings as applicable.
3. Construction authority representative and Contractor authorised representative shall
sign approved Contractor piping completion form (GOC form MP1).

11.1.11. Nonmetallic pipe

11.1.11.1. General
a. Nonmetallic piping systems shall be designed and installed in accordance with respective
piping code for material being installed.
b. Nonmetallic piping systems shall be inspected and tested in accordance with appropriate
clauses of 11.1.1 through 11.1.11.
c. Special inspection and test requirements particular to non metallic piping systems are listed
in clause 11.1.11.2.

11.1.11.2. Special inspection requirements


a. Installation, including joining, burial, anchoring, guiding, and supporting, shall be in
accordance with manufacturers recommendations.
b. Piping joints shall be made by fabricators/installers that have been certified by piping
manufacturer.
c. Pipe, fittings, and adhesive shall be produced by same manufacturer.
d. Material shall be verified that it meets fire classification code, if required.
e. Potable water piping shall have Health Certification.
f. Piping shall have proper span between supports and support location with no sags.
g. Support design shall be in accordance with manufacturer guidelines.
h. Pipe and fittings shall be protected from potential abrasion or crushing at support points.
i. Suspended piping shall be allowed to move freely.
j. Piping shall be anchored properly to keep piping positioned between loops and turns.
k. Fittings shall not fall directly on supports.
l. Valves should be directly anchored and expansion loops shall be installed in accordance
with installation drawing.
Note thermal expansion is greater than metallic pipe.
m. Thrust restraint shall be properly installed, if required.
n. Guides shall be installed in accordance with installation drawing, if required.
o. Proper gaskets shall be installed to meet piping service.
p. Interfaces with metallic tanks, vessels, equipment, or piping shall be by flanged (i.e.
mechanical) connection.
q. When connected to metallic pipe, metallic pipe shall be securely anchored at point of
connection such that expansion and contraction or weight of metallic piping is not
transferred to nonmetallic piping.
r. Pads or bonded saddles shall be used at supports to deter wear.

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s. Nonmetallic piping systems shall be properly earthed/grounded to adjacent steelwork for


installations in hazardous areas where build-up of static electricity may be a concern.

11.1.11.3. Special test requirements


a. General
1. Guides and supports shall be in place before hydrostatic testing.
2. On buried applications, piping shall be partially backfilled, with joints exposed before
testing.
3. Joints shall be properly cured in accordance with manufacturer specifications before
pressure testing.
b. Hydrostatic testing
1. Test pressures shall not exceed 1,5 times rated operating pressure of lowest rated
component of piping system.
2. Nonpressurized systems shall have one (1) hour minimum standing water test.
3. Air shall be bled from system high points to prevent storage of energy which could
result in damage to system.
4. When filling and bleeding system, valves shall be opened and closed slowly to
prevent surges of water hammer.
5. If leak is found, system shall be depressurized, repaired, and retested.
6. Testing in cold weather shall be avoided due to possible embrittlement of nonmetallic
piping.
7. When draining system, high point vents shall be opened to prevent vacuum damage to
piping system that is not rated for full vacuum.
c. Air testing
Air testing of nonmetallic piping systems shall be avoided.

11.1.11.4. Certification of non-metallic piping


Certification of non-metallic piping systems shall follow clause 11.1.13, as applicable.

11.1.12. Drain lines

11.1.12.1. Pressure drains


a. Pressure drains refers to closed drainage system designed in accordance with recognised
piping code irrespective of system operating pressure.
b. Pressure drain systems shall be inspected and tested in accordance with appropriate clauses
of 11.1.1 through 11.1.11.

11.1.12.2. Closed low pressure non hazardous drains


a. Low pressure non hazardous drains are those in non flammable non toxic service operating
at 1 bar ga (15 psig) or below.
b. Drain system shall be correct material of construction in accordance with project
specifications.
c. Drains shall normally be tested for tightness by filling system with water or, alternately,
smoke test may be performed.

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d. 1 times maximum operating pressure criterion may be used (at inspector discretion) to
determine test pressure of systems with maximum operating pressures of 1 bar ga
(15 psig).

11.1.12.3. Underground sewers


a. Drain system shall be correct material of construction in accordance with project
specifications.
b. Before testing, lines shall be checked to ensure sewers are free from obstruction.
c. Underground pipework of cast iron or nonmetallic materials, manholes, and similar
underground chambers shall be hydraulically tested in accordance with BS EN 752-4.
d. If practical, testing shall be between manholes.
e. Short branches between manholes shall be tested as one system with main drain, and
manholes shall be tested separately.
f. Soffit (exposed underside) of pipe shall be well supported during test except at joints,
which shall be left clear to allow hand check for leaks.
g. Invert levels and falls shall be checked before backfilling.
h. Accessible cleanouts shall be provided at origin of each branch.
i. If clayware or plastic pipes are to be tested at hydraulic pressure greater than 3 m (10 ft)
head or 0,3 bar ga (4,4 psig), check shall be made on suitability of pipe to withstand
pressure.

11.1.12.4. Open drains


a. Open drains are those in nonflammable nontoxic service operating at atmospheric pressure.
b. Open drains shall normally be tested for tightness by filling system with water. Alternately,
smoke test may be performed.
c. Inspection shall either be manual or remote, depending on three main factors:
1. Size of pipes.
2. Type of effluent carried.
3. Whether system is open or closed.
d. Principles of inspection are same, regardless of whether manual or remote.
e. Drain system shall be correct material of construction in accordance with project
specifications.
f. Invert levels and falls shall be checked before backfilling.
g. Origin of each branch shall have accessible cleanouts.
h. Each open cup drain shall have p-trap or water seal control.
i. Proper vent piping (100 mm [4 in] minimum) shall be installed and properly labelled.
j. If required by project specifications, hydrostatic or hydraulic pressure (standing water
head) test shall be performed.

11.1.12.5. Certification for drain lines


To record that inspection and test requirements of clause 11.1.12 for in drain lines have been
performed satisfactorily and that checks and documentation are complete,
construction/maintenance authority shall complete approved Contractor piping completion form
(GOC form MP1).

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11.1.13. Certification
To verify that inspection and testing requirements have been performed satisfactorily and that
checks and documentation are complete, construction authority shall complete following on
approved Contractor forms, as applicable:
a. Welding completion form (GOC form MW1). See clause 10.3.
b. Piping completion form (GOC form MP1). See clauses 11.1.4, 11.1.5, 11.1.10, 11.1.11 and
11.1.12.
c. System flush form (GOC form SF1). See clause 11.2.2.
d. Joint integrity form (GOC form JI1). See clauses 11.1.6, 11.1.7, 11.2.4, and 11.2.5.

11.2. Commissioning

11.2.1. General
a. Commissioning procedure shall incorporate functional testing of piping and interfaces
within operational system.
b. Commissioning procedure shall include system flushing, leak testing, and joint integrity
certification.
c. Specific tests shall detail required testing for interfaces integrated to vessel (e.g., level
control, temperature control, pressure control, pressure relief, flow control).
d. Certification of interfaces shall be managed under appropriate discipline clause of this GP.
e. Before commissioning activities begin on system, following shall be completed and signed
off by construction and commissioning authorities on approved Contractor forms:
1. MC certificate (GOC form MC1).
2. Punch list (GOC form PL1).

11.2.2. System flushing

11.2.2.1. General
a. Purpose of flushing is to ensure that systems to be handed over are clean and free from
debris that may damage equipment.
b. System flushing may be done in conjuction with hydrostatic/pneumatic testing.
c. System flushing may either be construction or commissioning activity. In BP GOC,
flushing is listed as commissioning activity.
d. System flushing may be performed by construction authority under control of
commissioning authority.
e. In some cases, piping maybe fabricated and strength tested offsite and then installed in
field by Construction Contactor and may not be flushed until after MC handover.
f. In either case, procedures on system flushing in clause 11.2.2 shall be followed.

11.2.2.2. Preliminary
a. Lines shall be cleared of debris by flushing with water or blowing with steam or air, as
appropriate, taking into consideration safety, efficiency, and convenience.
b. Piping that cannot be adequately cleaned by flushing shall be cleaned by other methods
that may include dismantling and reinstallation, subject to BP approval before
implementation.
c. Flushing material and medium to be used shall be subject to BP approval before cleaning.
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d. Systems to be flushed shall be checked against P&IDs to identify items that require
removal before flushing.
e. Before flushing, subdivision of each system into flushing packs shall be agreed with
Contractor, together with requirements for equipment isolation and removal.
f. Systems open to atmosphere, which do not require flushing, shall be blown down to ensure
lines are not restricted.
g. Additional pretest requirements from asset specific and design house or engineering
support or BP specifications and international standards, such ASME B31.3, may be
considered and referenced over and above other requirements.
h. Pipe sections or systems that are short in length with pipe diameters sufficiently large may
be visually inspected in lieu of flushing.
i. Combination of flushing and visual inspection may be accepted and indicated on system
flush certificate.

11.2.2.3. System preparation for flushing


a. Equipment removal
1. Positive displacement meters (and their strainers), turbine meters, bursting discs, flow
nozzles, orifice plates, level gages, pressure gages, and safety and pressure relief
valves shall be removed or blanked off before flushing and testing.
2. To avoid straining piping, temporary spacers or spool pieces shall be fitted to
complete pipework.
3. Temporary spool pieces shall be same internal diameter as piping.
4. Temporary fittings shall comply with specification of system being tested and be
clearly identified for later removal.
5. Impulse piping to instruments shall be disconnected from instrument downstream of
first block valve during flushing and testing of main process lines.
6. Analyser sampling systems shall be disconnected.
b. Speciality items and fittings, if removed, shall be wrapped in protective material and
securely tied to location.
c. Inline service strainers shall be removed before flushing and replaced after flushing is
complete.
d. Temporary strainers and filters
1. Operator advice and agreement shall be obtained on mesh size, type, and location of
temporary strainers and filters.
2. Record of temporary devices shall be kept to ensure they can be accounted for after
removal.
3. Devices shall have tabs that project at least 75 mm (3 in) beyond retaining flanges
such that they can be readily seen.
e. Control valves
1. Control valves and softseated valves shall be removed before flushing.
2. If removal of valves is not possible, internal fittings shall be removed but only after
BP approval.
3. Flushing is not permitted through control valves with low noise trim.

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4. If items are removed, temporary spool pieces shall be fitted to complete pipework to
avoid straining piping.
5. Temporary spool pieces shall have same internal diameter as piping.
6. Temporary fittings shall comply with specification of system being flushed or tested
and be clearly identified for later removal.
f. Sprinkler piping
1. Sprinkler piping shall be flushed and then plugged for pressure testing.
2. Heads, rosettes, and nozzles shall be fitted after flushing.
g. Pipe supports
1. Pipe supports and anchors shall be fitted before flushing and pressure testing.
2. Temporary supports required during fabrication and erection shall be removed.
3. In certain cases, additional pipework supports may be required due to weight of
flush/testing medium.
4. Design, position, and loadings for both temporary supports and pipework and their
foundations shall be subject to BP approval.
h. Expansion joints of sliding sleeve or bellows type and spring hangers shall have temporary
restraints to limit lateral movement.
i. Battery limits and offtakes shall be isolated by blinding or locked closed valves and
hazardous warning signs posted.
j. Temporary blinds, spectacle blinds, or orifice plates that are installed, turned, or removed
shall be entered in respective registers.

11.2.2.4. Flushing and test preparation specifics


a. Lines shall be flushed to low point in system.
b. Flushing shall not be performed through filters, vessels, machinery, equipment, orifice
plates, non return valves, control valves, or speciality items unless approved by BP for
conditions described in d and e.
c. Flushing with equipment, vessels, and tanks online is permitted if pressure and weight of
flushing medium can be tolerated and any internal instruments, fittings, or other devices
that would be subject to damage have been removed.
d. Separators, heat exchangers, and similar vessels may be used as paths for flushing but
upstream piping shall have suitable metallic permanent or temporary strainers or lines shall
be flushed with equipment isolated.
e. If flushing through pump is required, temporary strainers shall be installed. Otherwise,
piping spools and valves shall be dropped out and deflectors shall be provided to prevent
debris from entering pump.
f. Debris shall not be flushed into vessels, equipment, or dead ends.
g. If control valve location is used as flushing out point, entire control valve shall be removed
before flushing.
h. High points shall have vents to expel air.
i. Low points shall have drains.
j. Air or steam blowing
1. If air or steam blowing is used, special precautions regarding exhaust area and thrust
on pipework shall be considered and identified.
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2. Special attention shall be paid to ensure that electrical, electronic, or other equipment
adjacent to or below exhaust is not deluged.
k. Chemical cleaning
1. Chemical cleaning of systems (e.g., machinery seal oil or lubrication oil systems) may
be specified in some cases.
2. In these cases, special procedures shall be subject to BP approval.
l. Inline valves
1. Inline valves shall be in fully open position during flushing.
2. Check valves shall have either disc removed or be jacked open for flushing and
pressure testing.
3. Every effort shall be made to remove wafer type check valves.
4. If removal of wafer type check valves is not possible, internal flap shall be removed
(not tied back).
5. On reinstatement, internals of valves shall be checked for cleanliness and damage.
m. Test media
1. Checks shall be performed to ensure that system and line items can safely withstand
specified system flushing pressure and weight if full of water or other test medium.
2. Particular attention shall be given to possibility and prevention of overstressing
tubesheets that were designed on differential pressure basis.
3. If vessels so designed cannot support full head of water or if foundations or
supporting structures impose weight limit, vessel may be included in flush by
partially filling with water and introducing air or nitrogen blanket.
4. Detailed procedure for such flushing (including safety precautions to be taken) shall
be prepared by Contractor, subject to BP specialist vessel engineer approval.
5. Means shall be provided to prevent flushing pressure from being exceeded.
a) Recommended approach shall be to install relief valve to protect vessel during
flushing of adequate capacity set at 10% above test pressure on fluid supply
system.
b) Safety valve shall be capable of discharging capacity of the charging system at
test pressure.
n. If relief valve from vessel is used for this purpose, spring having correct pressure range
shall be fitted for test period. After testing, relief valve shall be reconfigured with original
spring and recalibrated to original set pressure, tested, and reinstalled.
o. Spring hangers and supports
1. After system is filled for flushing, spring hangers and supports shall be checked and
reset.
2. Spring hangers shall be blocked if flushing steam or gas lines with liquid.
p. Flush rates
1. Flush rates shall be high enough to remove heavy debris.
2. If flushing medium is water, flow velocities shall be 1,5 to 2 times normal operating
velocity or 3 m/sec to 4 m/s (10 ft/sec to 13 ft/sec), whichever is greater, if possible.

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q. Water flushing medium


1. Flushing shall be performed with clean fresh water, potable water, or treated
seawater, as appropriate.
2. For systems containing austenitic stainless steel piping and fittings, chloride ion
content of water shall be less than 50 ppm.
3. Carbon steel pipework flushed with sea water shall be dried immediately after
flushing to prevent corrosion.
Additional guidance on treatment of hydrotest water is in GP 06-29.
r. Air or steam flushing medium
1. If flushing medium is air (oil free and dry) or steam, flow velocity shall not be less
than 20 m/sec (65 ft/sec).
2. Records of flushing shall be maintained by colour marking P&ID to define system
flushing circuits, direction of flow, scope, equipment isolation, and prime mover
used.
s. Flushing or blowing shall continue until required cleanliness of system is attained.
t. Flushing outlets
1. Flushing outlet connections shall have basket for trapping debris.
2. Precautions shall be taken to ensure water is safely drained away while flushing.
3. Deflectors shall be provided, if necessary, to prevent refuse from entering open
equipment or machinery.
4. Flush shall be to open end, if possible.
5. Flexible hose or pipe, if required to route medium away, shall be at least same
diameter as piping.
6. Area of flush discharge shall be cordoned off and hazardous warning signs shall be
posted.
u. Flushing shall be performed through every dead leg equipped with drain valve to remove
debris.
v. Flushing of interconnecting piping shall be in direction of fall (high to low) and from
smaller piping to larger to ensure no debris is left trapped in dead legs.
w. On reinstatement, system shall be checked against P&ID, blinding and orifice register, and
then master P&IDs shall be updated. See clause 11.1.10 for reinstatement and piping
completion procedures.

11.2.2.5. Certification of flushing


To record that inspection and test requirements of clause 11.2.2 have been performed
satisfactorily and that checks and documentation are complete, commissioning and OA in
conjunction with construction authority shall complete following on approved Contractor form:
a. System flush form (GOC form SF1).
b. System flush form shall be used for verifing that complete system has been flushed before
or after pressure (strength) testing or leak testing (or completion of witnessed joint as
appropriate) and before line is placed in service.

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11.2.3. Leak testing (tightness test)

11.2.3.1. Preliminary
a. Purpose of leak test is to ensure integrity of system before handover.
b. Leak test shall be performed on pressurised process and utility systems (e.g., piping,
equipment, and vessels).
c. Pneumatic leak testing shall not be performed unless integrity of system has been
confirmed by hydraulic strength test.
d. Detailed leak test procedure shall be prepared for commissioning authority, subject to
commissioning authority and BP approval.
e. Procedure shall include:
1. Marked up P&IDs showing system limits of leak test.
2. Equipment to be included in each system.
3. Determination of test pressure.
4. Test medium, as follows:
a) Air.
b) Potable water (preferred).
c) Water injection water.
d) Nitrogen.
e) Nitrogen and helium.

11.2.3.2. Test preparation


a. Safe system of work
1. Permit to work shall form part of commissioning procedure and shall be in place
before testing begins.
2. This ensures that, after completion of pressure and leak testing, pressure inside
system is reduced to atmospheric level or as justified by risk assessment to
appropriate safe level before work starts on system.
3. Before work begins, commissioning authority shall verify that on every occasion,
system has safe working conditions.
4. Supply valve
a) Valve on pneumatic (e.g., nitrogen) supply line to system shall be locked in
closed position and blinded off if work is to be performed on system.
b) Disconnection of line to system is preferred.
c) Supply valve closure or disconnection is prerequisite of permit to work and shall
be signed as complete before start of work on system.
5. Pressure relief valve
a) If pneumatic test pressure is above MAWP or pressuring source could exceed
MAWP, test equipment shall have pressure relief valve.
b) Pressure relief valve shall be set to relieve marginally above test pressure.
c) Pressure relief valve shall be of adequate discharge capacity to relieve volume
supplied by pressuring source to safe area.

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ASME B31.3 paragraph 345.5.2 states: A pressure relief device shall be provided,
having set pressure not higher than the test pressure plus the lesser of 3,5 bar
(50 psi) or 10% of the test pressure.
6. Commissioning authority shall ensure adequate training of personnel involved in leak
testing and provide test personnel with approved written procedures.
7. Clamps or bolts on bolted flanges shall not be loosened while system is under
pressure. If required, system shall be isolated from pressure sources, depressurised,
and vented.
a) Clamps shall then be removed strictly in accordance with Vendor procedures.
b) Clamps shall only be removed by competent persons who have been trained in
Vendor assembly and disassembly procedures.
b. For test, unit pipework, vessels, and heat exchangers shall be linked by opening
appropriate valves, except that:
1. Pump suction and discharge valves shall be closed.
2. Pressure gages and instruments unsuitable for test pressure shall be isolated.
3. Systems for steam, air, fuel oil, fuel gas, and water shall be tested separately.
c. Vacuum test
1. If any part of unit will be under vacuum conditions, additional test shall be
performed.
2. Vacuum test shall also be performed if necessary to evacuate for purging.
3. Test shall begin at maximum vacuum and continue for 6 hours during which loss of
vacuum shall not exceed 15 mbar/hour (0,22 psi/hour) or 11 mm Hg/hour
(0,43 in Hg/hour).
d. Catalytic units
1. For catalytic units equipped with ejectors and if catalyst can be damaged by cold oil,
water, or steam, vacuum test of heater and reactors shall be performed.
2. Test shall begin at maximum vacuum and loss of vacuum shall not exceed
35 mbar/hour (0,51 psi/hour) or 25 mm Hg/hour (1 in Hg/hour).
3. Catalytic units not so equipped shall be pressure tested with nitrogen.
e. Outstanding items on punch list that would affect integrity of leak test shall be cleared.
f. Test limits as defined in commissioning procedure shall be implemented.
g. Adjoining systems shall be isolated by blinding or venting to prevent pressure buildup.
h. Valves shall be checked for freedom of movement.
i. Valves internal to system shall be open.
j. Internal components designed for operating at differential pressures shall be identified and
procedures shall be established, documented, and followed to protect them from higher
than design differential pressure if test pressure is applied to only one side of component.
k. Instrumentation shall be installed and opened to leak test.
l. Atmospheric vents and drains shall be isolated or blanked.
m. Insulation, cladding, or blankets shall remain uninstalled from flanges, valves, threaded
joints, connections, closures, etc., until leak tests are complete.
n. Test equipment and system pressure limiting devices, such as pressure relief valves, shall
be set to correct pressure.
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o. Sufficient pressure monitoring to avoid test pressure remaining undetected behind check
valves and similar equipment shall be used.
p. Fully operational newly calibrated pressure indicator (PI) of suitable range shall be fitted at
or near each venting position, injection positions and, wherever possible, near places where
work will be performed.
q. Pressuring point shall be selected to ensure that entire system is pressurised. Back flow
through non return valve (e.g., check valve) shall not be possible.
r. Venting
1. There shall be sufficient venting positions to prevent fluid being trapped behind non
return check valves, in dead legs, or between isolation valves.
2. Leak test procedure shall describe how system can be safely tested and vented in
discrete sections.
3. If this is intended method of testing, piping shall be adequately marked such that each
test section can be identified.
4. If section under test terminates at valve, assessment shall be performed to determine
if block and bleed or blind arrangement shall be used to prevent buildup of pressure
inside adjacent section.
s. Area surrounding system under test shall be suitably cordoned off and designated Keep
Out by warning signs and barriers. Testing shall not begin until nonessential personnel are
in safe area.
t. Only personnel essential for operation of test equipment shall be allowed in test area
during pressurisation and depressurisation.
u. If appropriate, radio or PA announcement that leak test is ongoing should be made.
v. Under no circumstances shall system under test be left unattended once system is
pressurised.
w. As with any pressure test, system shall be pressurised slowly and in stages (especially high
pressure systems) and pressure of system shall be recorded at various stages. See
clause 11.1.5.4 for pneumatic testing guidelines on pressurisation.
System is now ready for leak testing.

11.2.3.3. Test procedure


Items in clause 11.2.3.2 shall be verified before testing begins.
a. Leak test
1. Leak test is performed to prove pressure tightness (e.g., fitness for service) of joints,
seals, and glands each time integrity of containment systems is broken, either at
hookup, commissioning, or post operations.
2. Prevention of even minor leaks is particularly important if flammable or toxic fluids
are concerned.
b. Gross (preliminary) leak test using instrument air or nitrogen up to maximum of 6,9 bar ga
(100 psig) is often used at early stage of hookup and commissioning as means of
identifying large leaks before performing actual leak tests.
ASME B313., paragraph 345.1.2(c) recommends that no more than 1,7 bar ga
(25 psig) air test shall be made before hydrostatic test to locate major leaks.

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c. Hydraulic leak test


1. Hydraulic leak test shall be performed in preference to pneumatic leak test because of
lower energy of hydraulic fluid.
2. If pneumatic testing is proposed, risk assessment shall be performed before test and
shall be subject to BP approval.
d. Piping designed for vapour or gas shall have additional temporary support as necessary to
support weight of test liquid.
e. Pneumatic leak test
1. Pneumatic leak tests with inert gas are used extensively for piping systems that are
predominantly gas producing and for some offsite locations both during
commissioning and post operation phases before introduction of hydrocarbons.
2. Accepted norm for these tests is to pressurise with 99% nitrogen and 1% helium
tracer gas. Specialist leak test Contractor is normally employed for such tests.
3. Leakage is measured by equipment sensitive to tracer gas or by sonic or ultrasonic
detector devices.
4. Typical acceptable leakage rate shall be from 0,57 standard m3/year (20 standard
ft3/year) to 2,26 standard m3/year (80 standard ft3/year).
5. Consideration shall be given to ensure that during nitrogen injection and bleeding,
temperature does not fall to level where loss of structural integrity could occur in test
piece due to autorefrigeration.
f. Leak testing shall be performed at either:
1. 110% MAWP.
2. 95% of system relief valve set pressure if relief valve with set pressure below 110%
MAWP is in system.
g. Service leak test
1. Service leak test using service fluid rather than 110% MAWP test is acceptable
method of testing for leaks during post operations phase on low pressure systems,
such as instrument air, potable water, and diesel distribution systems that are
classified as Category D fluid service by ASME B31.3.
2. Service leak test may be used on hydrocarbon systems if pneumatic or hydraulic test
is impractical and risk assessment has been completed, subject to BP approval.
In ASME B31.3, Category D is fluid service for which all the following apply:
Fluid handled is nonflammable, nontoxic, and not damaging to human tissues as
defined in ASME B31.3.
Design gage pressure does not exceed 1 035 kPa (150 psi).
Design temperature is from 29C (20F) to 186C (366F).
h. For pneumatic leak test, following procedures are from AMSE B31.3, paragraph 3.45.5.5:
1. Pressure shall be gradually increased until gage pressure is reached that is lesser of
one half test pressure or 170 kPa (25 psi), at which time preliminary check shall be
performed, including examination of joints for leaks (e.g., flanges, valve glands).
2. Thereafter, pressure shall be gradually increased in steps until test pressure is reached,
holding pressure at each step long enough to equalise piping strains.
3. At each pressure stage, pressure shall be recorded and system shall be checked for
leaks until final test pressure is reached.

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4. Pressure shall then be reduced to design pressure before examining for leaks.
i. For water filled systems, it is important to ensure all air is vented and system is completely
water filled.
j. Final test pressure shall be held for at least 30 minutes with no visible leaks to atmosphere
before detailed inspection is performed.
k. Soapy water shall be used to bubble check for air or nitrogen tests.
l. If repairs or replacements are needed during tests, leak test shall not be considered
complete until required repairs and replacements have been made and system has been
retested, subject to BP approval.
m. Pressures shall always be checked and following shall be recorded immediately before
start of further work on system:
1. Completion of test.
2. Isolation from pressure source.
3. If depressurisation or venting has occurred.

11.2.3.4. Test completion


On completion of tests, following action shall be taken:
a. For pneumatic tests, system shall be slowly depressurised to prevent autorefrigeration.
b. Work permit shall be returned.
c. If appropriate, radio or PA announcement shall be made that leak testing is complete.
d. Pressuring connection shall be removed, while including or indicating joints on connection
or vents that will become witness joints and require inclusion in certification (service test),
if applicable.
e. Barriers and warning signs shall be removed.
f. Approved Contractor system leak test certificate (GOC form SL1) shall be completed,
including attaching markup of relevant P&ID indicating system limits.
g. For each tagged flange, data shall be recorded as who witnessed leak test and leak test
number.

11.2.4. Service testing


a. Service test requirement
1. Service test shall be required on high risk piping or if it would be impractical to leak
test system on completion of workscope.
2. Service test shall be in conjunction with critical joint installation procedure (see
clause 11.1.7) and joint integrity procedure (see clauses 11.1.6 and 11.2.5).
3. Service test shall use process fluid to test piping for leaks.
4. Service test shall not be performed until:
a) All stages of critical joint installation and joint integrity procedure have been
completed.
b) All outstanding items on punch list that would affect system integrity have been
cleared.
b. Joints that were split shall be closely scrutinised for leaks (i.e., fluid leakage, soapy bubble
in gas systems, and gas detection for hydrocarbons) during early stages of pressurisation.

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c. Joints under scrutiny for leaks shall be observed until desired pressure (i.e., normal
operating pressure) is achieved.
d. Relevant parts of approved Contractor joint integrity certificate (GOC form JI1) should be
signed off upon completion. Refer to clause 11.1.6 for details.
e. Service test documentation
1. If service test is performed instead of leak test, waiver or concession shall be granted
by approving authority or OA.
2. System leak test certificate (GOC form SL1) shall not be created.
3. Joint integrity certificate (GOC form JI1) shall record that waiver was given.
4. In place of system leak test number, EQ, TQ, or operating query (OQ), identification
number shall be recorded in system leak test number box.

Note: Critical joint installation shall always be followed by service


test.

f. Flange and joint tagging procedure or system leak test shall not be required in service test
for piping with low risk potential that may contain following:
1. Seawater.
2. Firewater.
3. Plant air.
4. Instrument air.
5. Domestic waste.
6. Potable water.
7. Municipal water.
8. Industrial water.
g. Quality of work is still important on low risk systems and shall be subject to inspection and
service testing to ensure TI has been achieved and maintained.
h. Service test required
1. Service test shall be required for systems where operating pressure is above 6,9 bar ga
(100 psig) for water and 1 bar ga (15 psig) for air.
2. Joint integrity form (GOC form JI1) shall be created accordingly. Refer to
clauses 11.1.6 and 11.2.5 for full details.
i. Service test not required
1. If operating pressure is below 6,9 bar ga (100 psig) for water and 1 bar ga (15 psig)
for air, formal testing or certification is not required.
2. Activity shall be recorded as follows:
a) In maintenance management system if applied to maintenance activities.
b) In MC certificate (GOC form MC1) and system handover certificate (GOC form
SH1), if applied to projects or modifications.

11.2.5. Joint integrity testing


a. See clause 11.1.6 for details on joint integrity testing.
b. For commissioning phase, following shall be completed:

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1. Leak testing in accordance with clause 11.2.3.


2. Joint integrity certificate (GOC form JI1 Part B) to be available for post test integrity
service tests.
Completion of Part A and B of GOC form JI1 is needed before system handover
certificate can be signed and equipment can be safely operated.

11.2.6. Certification
a. To record that checks and documentation are complete and that requirements of
clause 11.2 have been performed satisfactorily, following shall be completed by
commissioning authority and OA on approved Contractor forms, as applicable:
1. Leak test form (GOC form SL1). See clause 11.2.3.
2. System flush form (GOC form SF1). See clause 11.2.2.
3. Joint integrity form (GOC form JI1). See clauses 11.1.6, 11.1.7, 11.2.4 and 11.2.5.
b. Functional testing shall be documented on forms, subject to BP approval.

12. Unfired pressure vessels

12.1. Inspection and testing

12.1.1. Scope
Requirements of this clause apply to unfired pressure vessels, including pressure storage tanks
and heat exchangers (for which further specific requirements are in clause 13).

12.1.2. Site fabricated vessels

12.1.2.1. General
a. Requirements for inspection and pressure testing of site fabricated vessels during
fabrication are in GP 32-10[mkm4],[JRF5] except that inspector shall assume duties of
independent inspection authority unless it is decided to employ such inspectorate.
b. Special requirements for site pressure testing are also in clause 11.1.5.

12.1.2.2. Pressure testing


a. Requirements for pretest cleaning and constraints imposed on choice of testing medium are
in clause 11.1.4.
b. Test pressure shall comply with specified design code.
c. Post test venting, draining, drying, remaking of broken flanged joints, and fitting of
pressure relieving devices shall comply with clause 11.1.10.

12.1.3. Offsite fabricated vessels

12.1.3.1. General
This clause covers inspection procedures for pressure vessels and atmospheric tanks fabricated
and tested in Vendor facilities.
See GP 46-01 for additional guidance.

12.1.3.2. Field checklist


Following shall be checked on receipt in field:

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a. Vessel shall be initially inspected for transit damage (especially small nozzles and vessel
internals) and for installation damage after placement. Also see clause 7.
b. Vessel shall be inspected for general condition and cleanliness. Also see clause 9.7.
c. Temporary attachments
1. Temporary attachments that facilitated transport shall be removed and welds shall be
ground flush and inspected by NDE.
2. If attachments were welded to pressure envelope, appropriate corrective action shall
be taken.
d. Vessel shall be correct in all respects to Vendor drawings and data sheet.
e. Vessel shall comply with specification (material and test certificates, nameplate,
dimensions, and adequacy of access). Also see clause 7.1.b.
f. Special attention shall be paid to refractory lined vessels and reactors to ensure compliance
with specification and design with regard to refractory and method of attachment.
g. Before vessel placement, foundation and structural support construction shall be checked
for compliance with design drawings, specifications, and completion.
h. PSVs shall be installed correctly and shall be in certification.
i. Expansion end bolting shall be properly assembled.
j. If vessel is within piping pressure test pack:
1. Construction authority mechanical engineer shall verify existence on site of dedicated
vessel test certificate and ensure IRN is in place for vessel.
2. Piping system test pressure shall be compared with vessel pressure.
3. Construction authority mechanical engineer shall ensure that pressure ranges are
compatible before authorising inclusion of vessel in piping system test.
k. Above shall equally apply to preassembled units (PAUs) incorporating such vessels.

12.1.4. All vessels


In addition to specific procedures, following shall be checked on vessels and tanks fabricated
offsite or modified onsite (with digital pictures of vessel internals highly recommended as part
of inspection record):
a. Inspections shall comply with applicable codes, standards, and specifications.
b. Vessel platforms, ladders, and access arrangements shall be inspected by construction
authority mechanical engineer to ensure compliance with design drawings, specifications,
standards, and safety aspects.
c. Construction and commissioning authorities (with OA invited to attend) shall perform
internal inspection of vessel to confirm cleanliness, damage free condition, and completion
of internal installation to specification, including following:
1. Demisting pads.
2. Trays.
3. Coils.
4. Baffles.
5. Vortex breaker.
6. Lining.
7. Packing.
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8. Internal nuts (suitably locked).


d. Internal coating shall be checked by qualified coatings inspector.
e. Insulation shall be correct and complete.
f. Instrumentation shall be visible and accessible.
g. Earthing/grounding and bonding shall be correct.
h. Piping connections and manways shall be correctly bolted up and correct specification
gaskets installed.
i. Holding down bolts
1. Holding down bolts shall be correctly tightened and torqued.
2. After installation, holding down arrangement of horizontal vessels shall comply with
special design requirements for expansion.
j. Details of vessel identification plate shall be correct.
k. State registration (if applicable) shall be complete and shall have number assigned.
l. Punch lists
1. Before final vessel closure, construction and commissioning authorities, with OA
invited to attend, shall inspect vessel internally.
2. Discipline punch listing shall be created (as applicable) and relevant punch list forms
(GOC form PL1) shall be generated.
m. Vessel manufacturer material data reports (MDRs) shall be available.
n. Wall thickness
1. Before insulation installation, baseline wall thickness measurements shall be taken (if
applicable) and recorded on approved BP forms.
2. Inspection points shall be agreed with inspection authority as in clauses 11.1.3.2 and
11.1.3.3.
3. Corrosion coupons (if required) shall be correctly installed.
o. If vessel is subject to non thinning damage mechanism, baseline inspection shall be
completed as specified by inspection authority.
p. Foundations and supports
Following shall be checked:
1. Dimensional correctness of concrete foundations, supporting steelwork, and holding
down bolts (diameter, length, spacing).
2. If necessary, bolting material.
3. Provision of drainage from within vessel skirt.

12.1.5. Site pressure testing

12.1.5.1. Scope
a. Requirements of this clause apply to vessels undergoing individual pressure tests on site.
b. Inclusion of vessels in piping system pressure tests is covered in clause 11.

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12.1.5.2. Specific test requirements


Offsite fabricated vessels constructed in accordance with recognised pressure vessel code
(which implies their having undergone properly certified shop pressure test) shall not require
individual pressure tests at site except in following cases:
a. Vessels whose condition resulting from transport, storage, handling, or for other cause is
suspect in opinion of inspector.
b. Vessels that have had any site modification or repair that, in opinion of inspector,
necessitates site pressure test or are necessitated by regulatory requirements.
c. Vessels that have been constructed or assembled on site (see clause 12.2).
d. Vessels that may already have been tested in Vendor works but are required to be retested
on site after installation to satisfy regulatory requirements.
e. If Vendor certified test certificates are not available.

12.1.5.3. Test constraints


Constraints outlined in clause 11.1.5 are applicable to pressure vessel testing.

12.1.5.4. Witnessing
Pressure tests shall be witnessed by inspector.

12.1.5.5. Test pressure and duration


If test pressure and duration differ from code requirements, parameters shall be agreed with BP.

12.1.5.6. Preparation for testing


a. Vessel relief valves shall be removed or positively isolated.
b. Plugs shall be removed from telltale holes in reinforcing rings and pads.
c. Joints shall be free from paint, insulation, or other covering or coating.

12.1.5.7. Pneumatic testing


a. If vessels are designed such that they cannot support full head of water or if foundations
impose weight limitation, pneumatic or combined hydrostatic and pneumatic test may be
necessary.
b. Test procedure, including safety precautions, shall be subject to BP approval.
c. If vessels are pneumatic tested or hydraulic and pneumatic combined tested, relief valve
shall be fitted to protect vessel during test.
d. If relief valve from vessel is used for this purpose, spring having correct pressure range
shall be fitted for test period. After testing, relief valve shall be reconfigured with original
spring and recalibrated to original set pressure, tested, and reinstalled.

12.1.5.8. Foundation precautions


a. If tower is to be subjected to full hydrostatic test or to combined hydrostatic and pneumatic
test, Vendor (or other authority responsible for design of foundation) shall specify
maximum wind speed that can be tolerated with vessel full (or partly full) of water.
b. For hortonspheres or any other large vessels that are to be tested in field, base level
readings shall be taken on each supporting column before, during, and after filling with
water and emptying.

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12.1.6. Fractionation columns

12.1.6.1. General
a. Clause covers additional tests required for trayed and packed columns.
b. Tests shall be witnessed by Inspector. Inspector in this case may be process person.

12.1.6.2. Trayed columns


a. Following shall be checked against specified tolerances:
1. Under downcomer clearance.
2. Weir height.
3. Tray levelness.
b. Unless specified otherwise, tolerance in GIS 46-040 shall apply.
c. Leak tests in d. shall be performed with liquid level at top of risers, with category of test
subject to BP specification.
d. Following shall apply for accumulation trays:
Category Typical application Max acceptable rate of level drop
(mm/hour) (in/hour)
1 Vacuum towers with lowest distillate draw 10 0,4
2 Vacuum towers except category 1 50 2,0
3 All other towers 200 8,0

e. For bubble cap trays:


1. Use rate given for Category 3.
2. Drain holes shall be plugged if necessary.
f. Replacement of tray manways shall be witnessed by inspector, with operator invited to
attend.

12.1.6.3. Packed columns


a. Distributor level shall be checked against design tolerances. Unless specified otherwise,
tolerance of 2 mm (0,078 in) maximum difference from high to low point shall be used.
b. If distributor design is such that individual components are levelled separately, tolerance in
a. shall apply to each component and to components collectively.
c. Flange bolts shall be checked for tightness.
d. Spray nozzles shall be installed after distributor has been assembled in column. Nozzles
shall be checked for tightness.

12.1.7. Certification
a. To ensure installation complies with drawings and specifications, record that vessel checks
and documentation are complete and requirements of clause 12.1 have been performed
satisfactorily.
b. Approved Contractor vessel installation form (GOC form MV1 Side 1) shall be completed
by construction and commissioning authorities for each installed vessel.

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12.2. Commissioning

12.2.1. General
a. Commissioning procedure shall incorporate functional testing of pressure vessels within
operational system, together with leak testing and joint integrity certification.
b. Specific functional test shall detail required testing for interfaces integrated to vessel (e.g.,
level control, temperature control, pressure control, flow control). Certification of these
interfaces shall be managed under appropriate clauses of this GP.
c. Before commissioning activities begin on system, following shall be completed and signed
off by construction and commissioning authorities on approved Contractor forms:
1. MC certificate (GOC form MC1).
2. Punch list (GOC form PL1).
d. Leak test shall be performed to ensure integrity of system before handover.
e. Leak test shall be performed on process and utility piping systems, equipment, and vessels.
f. Leak testing shall be performed as specified in clause 11.2.3.

12.2.2. Joint integrity testing


a. See clause 11.1.6 for details on joint integrity testing.
b. For commissioning phase, following shall be completed:
1. Leak testing shall be performed in accordance with clause 11.2.3.
2. For each flange, threaded connection, gland, or packing, data shall be recorded as
who witnessed leak test and leak test number.
Completion of Parts A and B of GOC form JI1 is needed before system handover
certificate can be signed and equipment can be safely operated.

12.2.3. Certification
a. To record that checks and documentation are complete and that requirements of
clause 12.2 have been performed satisfactorily, and following shall be completed by
commissioning authority and OA on approved Contractor form:
1. Leak test form (GOC form SL1).
2. Joint integrity certificate (GOC form JI1), if required.
b. Functional testing shall be documented on BP approved forms.

13. Heat exchange equipment

13.1. Inspection and testing

13.1.1. Scope
This clause covers particular requirements for inspection and testing of all types of heat
exchange equipment.

13.1.2. Requirements
a. Requirements for inspection and testing of unfired pressure vessels in clause 12 shall apply
to heat exchange equipment as appropriate to particular type of heat exchanger and its
foundations and supporting structure.
b. Tubulars inserted into process towers or vessels shall be:
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1. Considered part of tower or vessel.


2. Subject to same inspection and testing requirements in addition to more stringent
requirements that may be applicable to tubular.
c. Dismantling
1. Dismantling shall not routinely be required, but if required in individual cases, bolted
bonnets and channels shall be removed or end covers or manhole covers removed
from fixed tube or plate exchangers. New joints shall be fitted on reassembly.
2. Special care shall be taken if expansion bellows are involved to ensure guide rod
settings are checked after testing.
d. Inspection and test requirements for any machinery associated with heat exchangers (e.g.,
cooler fans and drivers) shall comply with clause 16 as appropriate to particular type of
machinery and control equipment.
e. After installation, anchor bolts in slotted holes shall be backed off 3 mm (1/8 in).
f. Skid plates on floating end shall be greased as specified.
g. Before any system leak test, heat exchanger shall be checked to verify that preservation
materials have been removed.
h. To document installation of heat exchange equipment complies with requirements,
approved Contractor equipment installation form (GOC form MM1) shall be completed.
i. Outstanding items shall be punch listed on approved Contractor punch list form (GOC
form PL1).

13.1.3. Site pressure testing


a. Heat exchange equipment may be included in testing of piping system.
b. Requirements, limitations, and precautions are covered in clauses 11.1.5 and 11.2.3,
depending on what type of pressure test is to be performed.
c. Exchangers with carbon steel tubes shall be protected to avoid corrosion after wetting (see
clause 11.1.4.1.b).
d. Site pressure testing is required only in circumstances in clause 12.1.5.2.
e. Expansion joint stops shall be removed after hydrotest and before leak test.
f. Site pressure testing of heat exchangers may be performed individually or in groups or
banks of similar exchangers on same duty.
g. General requirements of clauses 12.1.5.3 to 12.1.5.6 shall apply.
h. Particular attention is drawn to need to prevent overstressing tubesheets that have been
designed on differential pressure basis. Appropriate design code shall be followed.

13.1.4. Post test remedial work and reinstatement


a. Rerolling
1. Leaks between tube and tubesheet may be remedied by rerolling.
2. Advice on appropriate parameters governing rerolling operation shall be obtained
from tubular Vendor.
3. Such repairs shall be performed in accordance with approved procedure and shall be
documented.
b. Particular attention shall be paid to ensuring that equipment is thoroughly dried to prevent
scaling or corrosion of tubes before commissioning.

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c. Fan blades shall be adjusted in accordance with Vendor instructions.

13.1.5. Certification
To record that checks and documentation are complete and that requirements of clause 13.1
have been performed satisfactorily, following shall be completed by construction authority, as
applicable, on approved Contractor forms:
a. Equipment installation form (GOC form MM1).
b. Joint integrity certificate (GOC form JI1). See clauses 11.1.6, 11.2.4, and 11.2.5.

13.2. Commissioning

13.2.1. General
a. Commissioning procedure shall incorporate functional testing of heat exchangers within
operational system it exits along with leak testing and joint integrity certification.
b. Specific functional test shall detail required testing for interfaces integrated to heat
exchanger (e.g., level control, temperature control, pressure control, flow control).
c. Certification of interfaces shall be managed under appropriate discipline clause of this GP.
d. Before commissioning activities begin on system, following shall be completed and signed
off by construction and commissioning authorities on approved Contractor forms:
1. MC certificate (GOC form MC1).
2. Punch list (GOC form PL1).

13.2.2. Air coolers


a. Motor to gearbox alignment shall be checked.
b. Alignment settings and checks shall be properly documented on approved Contractor
alignment forms and shall be subject to BP approval.
GOC form MM2 can be used to document this information.
c. Fan motors shall be initially run unconnected (no load) to verify compliance with specified
rotation direction and vibration level.
d. Fans shall be operated to verify compliance with specified amperage levels.

13.2.3. Leak testing (tightness test)


a. Leak test shall be performed to ensure integrity of system before handover.
b. Leak test shall be performed on process and utility piping systems, equipment, and vessels.
c. Leak testing shall be performed in accordance with clause 11.2.3.

13.2.4. Joint integrity testing


a. See clause 11.1.6 for details on joint integrity testing.
b. For commissioning phase, following shall be completed:
1. Leak testing shall be performed in accordance with clause 11.2.3.
2. For each flange, threaded connection, gland, and packing, data shall be recorded as
who witnessed leak test and leak test number.
If GOC form JI1 is being used, completion of Part A and B of form is required
before system handover certificate can be signed and equipment can be safely
operated.

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13.2.5. Certification
a. To record that checks and documentation are complete and that requirements of
clause 13.2 have been performed satisfactorily, following shall be completed by
commissioning authority and OA, as applicable, on approved Contractor forms:
1. Machinery alignment form (GOC form MM2).
2. Leak test form (GOC form SL1).
3. Joint integrity certificate (GOC form JI1). See clauses 11.1.6, 11.2.4, and 11.2.5.
b. Functional testing shall be documented on forms subject to BP approval.

13.3. Post startup performance testing

13.3.1. General
After system handover, plant performance testing shall be performed to verify design integrity,
expectations, and that facility is performing to those expectations for agreed upon time period.
See clause 27 for details.

13.3.2. Heat exchangers


To ensure that overall performance meets design requirements of facility, procedures for site
performance testing of heat exchangers shall be agreed upon between BP engineering and
contract design house.

13.3.3. Air coolers


a. If air cooled exchanger was not factory tested and site performance test is required, site
performance testing procedures for air coolers shall have been previously agreed upon with
Vendor and shall depend on extent to which coolers have been tested before delivery.
b. Test parameters shall include:
1. Thermal performance.
2. Air flow rate.
3. Structural stability.
4. Vibration.
5. Electrical power consumption.

13.3.4. Certification
See clause 27 for details of certification.

14. Fired heaters

14.1. Inspection and testing

14.1.1. Inspection of tubes and headers before and during erection


Heater coils with welded on headers or return bends are more common type of
installation. Alternative is tubes expanded into headers.
In clauses 14.1.2 through 14.1.4, as applicable, crossovers and crossover connections shall be
treated in same way as tubes and headers.

14.1.2. General requirements


Inspector shall:
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a. Check that materials for tubes, headers, and return bends comply with specifications (see
clause 9.8).
b. Ensure required measurements are correctly taken and recorded.
c. Choose points for baseline data (e.g., creep measurement data) as agreed upon with IA and
as in clause 11.1.3.
d. Ensure baseline ultrasonic thickness measurements are performed for following:
1. At intervals along tubes.
2. Along outer radii of return bends.
e. Ensure oil, rust, scale, and other debris are removed from heater and tubes.

14.1.3. Heater coils with welded on headers or return bends


a. Before being placed in position, each tube end and header or return bend shall be examined
for weld preparation, cleanliness, and freedom from defect, such as lamination or porosity.
b. Tube ends and headers or return bends shall be measured for wall thickness and ovality
before assembly.
c. Inspector shall verify that measurements are within acceptable tolerances to permit fit up
for welding.
d. Preparation, welding, PWT (as applicable) and radiography shall comply with:
1. GIS 42-101 for carbon steel pipework.
2. GIS 42-102 for stainless steel pipework.
e. If multi hole internal tube headers are installed, wall thicknesses and sizes of such header
bodies and end caps shall be measured and recorded.

14.1.4. Heater coils with tubes expanded into headers


a. Before being placed in position, each tube end and header shall be examined for
cleanliness, damage to header landings, and other defects.
b. Each tube end shall be free from pitting, lamination, flats, or mill scale.
c. Each tube end and its mating header shall be measured after tubes have been threaded
through tube support sheets.
d. Inside diameter (ID), outside diameter (OD), average wall thickness of tube end, and ID of
header lands shall be measured and recorded.
e. Expansion tests
1. Two expansion tests shall be performed on each size of tube using BP rolling chart in
accordance with Table 2 or other similar chart as may be agreed upon with BP, and
using actual expanders proposed.

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Table 2 - Tube rolling chart

Source: BP Starnard Drawing S-2032

2. Test expansion stub tubes and header shall be of same material to be used for coil.
3. Final expanded ends shall be sectioned by Contractor.
f. Expansion required
1. Inspector and Contractor shall mutually agree on amount of expansion required in
each case and modifications required (if any) to tube rolling chart.
2. Required expansion and actual expansion after rolling shall be recorded.
g. On completion of expansion, tubes shall be measured internally for ID at roll and at
300 mm (1 ft) along tube.
h. For convection bank tubes that are not externally accessible, bore of tubes shall be
measured along length by calipers and sizes recorded.
i. If tube ends are to be seal welded after expansion, tube ends shall be fly cut in accordance
with Table 3, except in those cases where inspector considers tube ends are in sufficiently
satisfactory condition that fly cutting may be omitted.

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Table 3 - Rolled tube connection with seal welding

Source: BP Standard Drawing S-1088

j. Before seal welding, tube ends shall be thoroughly cleaned and all traces of oil or grease
removed.
k. Seal welds shall be examined for cracks, porosity, or other defects with dye penetrants or
other means agreed upon with BP.
l. Header plugs and seat screws shall be treated with anti scuffing compound before
assembly.

14.1.5. Pressure testing


a. On completion of erection, heater coils shall be subjected to hydraulic pressure test that
shall be witnessed by inspector.
b. Test pressure shall comply with appropriate design code.
c. Test procedure
1. Test procedure shall be prepared by Contractor and submitted to BP. Procedure shall
be subject to BP approval.
2. Procedure shall include flushing, testing (including duration of test and test medium),
and post test reinstatement (including requirements for drying out).
3. Guidance on these matters, including test documentation, is in clauses 11.1.4 through
11.1.10.
d. Heater coils shall be spaded at inlets and outlets (heater side of valves if fitted) and
provision made for venting of air and for draining.
e. Heater coils designed to operate under vacuum shall, after hydraulic test, be subjected to
pneumatic leakage test at 1 bar ga (15 psig) with suitable gas using soapy water solution as
detector.
f. For heaters with seal welded expanded tubes, pressure test shall be performed after
completion of seal welding.
g. Heater shall be subjected to further leak test during commissioning (see clause 14.2.2).

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14.1.6. Heater linings, air preheaters, ducts, and stacks


a. Special examination for compliance with specifications and drawings shall be performed
during construction of refractory linings in heaters, ducts, and stacks.
b. Particular attention shall be given to ensuring:
1. Allowance for expansion.
2. Sufficiently heavy reinforcement has been used for refractory linings.
3. Reinforcement has been securely attached.
4. Reinforcement will remain at correct distance from casing throughout subsequent
refractory guniting operation.
c. Refractory shall be dried out in accordance with Vendor procedures.
d. Check shall be made to ensure that:
1. Paint specified for internal corrosion protection of lined casings and ductwork has
been applied.
2. Expansion joints in refractories are of required number and width and are fitted with
specified materials.
e. Dampers
1. Dampers and operating mechanisms shall be checked for free action through full
travel and to ensure they fail safe in open position.
2. Mechanism shall be match marked in this position and checked to ensure it indicates
true position of damper.
f. Air motors, if provided, shall be checked that they develop sufficient power to operate
dampers with normal air pressure available at point of application.
g. Immediately following erection, alignment and verticality of stack shall be verified and
recorded.
h. Heater enclosure and flue gas ducting shall be visibly leak-tight when tested with smoke
bombs under positive pressure of at least 12 mm (1/2 in) water gage.
1. Vendor shall provide equipment necessary for this test.
2. If heater is shop prefabricated into one or more sections then each section shall be
shop smoke bomb tested.
i. Combustion air side of flue gas or air heater shall be smoke bomb tested to at least 25 mm
(1 in) water gage.

14.1.7. Burners
a. Burner swirlers, quarls, dampers, gas guns and rings, and oil guns shall be visually
examined for signs of damage or blockage.
b. Burner installation shall be inspected to ensure that setting dimensions and tolerances
comply with requirements as shown on Vendor drawings.
c. Burner air registers or dampers shall be checked for free action through their full travel and
to ensure that external position indicators shows true position of register or damper.
d. If forced draught burners are installed, flow rate of combustion air to each burner shall be
checked to ensure it is within 3% of calculated average air flow rate per burner.

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14.1.8. Certification
To record that checks and documentation are complete and that requirements of clause 14.1
have been performed satisfactorily, following, as applicable, shall be completed by construction
authority and commissioning authority on approved Contractor forms:
a. Equipment installation form (GOC form MM1).
b. Joint integrity certificate, Part A (GOC form JI1).

14.2. Commissioning

14.2.1. General
a. Commissioning procedure shall incorporate functional testing of fired heaters within
operational system it exits along with leak testing and joint integrity certification.
b. Specific functional testing shall detail required testing for interfaces integrated to fired
heater (e.g., temperature control, pressure control, flow control).
c. Certification of interfaces shall be managed under appropriate clause of this GP.
d. Before commissioning activities begin on system, following shall be completed and signed
off by construction and commissioning authorities on approved Contractor forms:
1. MC certificate (GOC form MC1).
2. Punch list (GOC form PL1).
e. Items in commissioning procedures shall include:
1. Flame scanners shall be calibrated. Position of scanners shall be checked and adjusted
to detect flame with burner fired.
2. Burner management system instrument and interlock logic functionality and proper
operation shall be checked.
3. Burner management system shall be adjusted to actual flow rates and valve and
damper movement intervals.
4. Sootblower control system checkout shall include verification of blowing media
flows, system warmup interval, and cycle completion time. Cycle completion time
shall comply with permit requirements.
5. Environmental compliance test shall be performed for fired boilers and heaters.
6. Checks shall be documented on forms, subject to BP approval.

14.2.2. Leak testing (tightness test)


a. Leak test shall be performed to ensure integrity of system before handover.
b. Leak test shall be performed on process and utility piping systems, equipment, and vessels.
c. Leak testing shall be performed in accordance with clause 11.2.3.

14.2.3. Joint integrity testing


a. See clause 11.1.6 for details on joint integrity testing.
b. For commissioning phase, following shall be completed:
1. Leak testing shall be performed in accordance with clause 11.2.3.
2. For each flange, threaded connection, gland, or packing, data shall be recorded as
who witnessed leak test and leak test number.

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If GOC form JI1 is being used, completion of Part A and B of form is required
before system handover certificate can be signed and equipment can be safely
operated.

14.2.4. Preparation of fired heater for service


a. Pressure test
1. If valves have been provided at heater outlet for operational reasons, pressure test
using oil as test medium shall be performed at shutin head of heater feed pump.
2. Procedure shall be similar to that described in clause 14.1.5.
b. Heater refractory, including that of chimney, shall then be dried.
c. Procedure shall normally be that recommended by Vendor but shall be thorough enough to
ensure that heater can be brought on stream immediately at end of commissioning period.
Typical program for heater with design heat release of approximately 30 MW
(1x109 BTU/hour) would be as follows:
Pass steam or oil through coils. If steam raising coils are installed, feedwater is
circulated through them and steam is circulated through superheaters.
Purge heater combustion space with steam until steam has issued from top of
chimney for 15 minutes.
Drying is performed by any convenient means (e.g., portable warm air fans or
bottled gas burners). Chimney base temperature is allowed to rise steadily,
reaching about 120C (248F) after 24 hours. Main burners may be lit if
required for this purpose.
Thereafter temperature is increased by 25C (45F) increments at 12 hr
intervals up to 260C (500F). Temperature shall be maintained for 24 hr.

14.2.5. Certification
a. To record that checks and documentation for fired heaters are complete and that
requirements of clause 14.2 have been performed satisfactorily, following shall be
completed by commissioning authority and OA, as applicable, on approved Contractor
forms:
1. Leak test certificate (GOC form SL1).
2. Joint integrity certificate (GOC form JI1 Part B).
b. Functional testing shall be documented on forms subject to BP approval.

14.3. Post startup performance testing

14.3.1. General
a. After system handover, plant performance testing is performed to verify fired heater design
integrity and expectations and that facility is performing to those expectations for agreed
upon time period.
b. See clause 27 for details.

14.3.2. Certification
See clause 27 for details of certification.

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15. Tanks

Requirements of this clause cover atmospheric storage tanks of steel construction.


More detailed guidance on inspection and testing may be found in the following:
Nonrefrigerated petroleum and petrochemical liquids: GP 58-10, GP 58-20, and
BS EN 14015.
Refrigerated liquefied gases: GP 58-50 (future) and EEMUA 147.
Clause 15.1 covers all tanks, although particular subclauses of 15.1.5 may apply
only to certain types of tanks. Requirements for testing outlined in clause 15.1.8 are
generally applicable to all tanks, but there are additional special requirements for
tanks in refrigerated service.

15.1. Inspection and testing

15.1.1. General
In addition to other specific requirements, following shall be checked on tanks fabricated either
onsite or offsite:
a. Inspections shall comply with applicable codes, standards, and specifications.
b. Inspection results shall be recorded on approved BP forms.
c. Discipline punch listing shall be performed as applicable and recorded on approved
Contractor punch list form (GOC form PL1).
d. Tank installation shall comply with applicable drawings and specifications.
e. Details of tank identification plate shall be correct.
f. Tank Vendor material data reports (MDRs) shall be available.
g. Local registration shall be completed and appropriate identification number shall be
assigned.
h. Tank platforms, ladders, and access arrangements shall comply with design drawings,
specifications, standards, and safety requirements.
i. Construction and commissioning authorities (with OA invited to attend) shall inspect tank
internals (with digital photos highly recommended to document specifics) to confirm
cleanliness, damage free condition, and completion of internal installations in accordance
with specification and approved drawings, including following:
1. Vortex breakers.
2. Internal linings and coatings (to be verified by coating inspector).
3. Internal or external floating roof, as follows:
a) Pontoons tested and have adequate number of compartment manholes.
b) Shell and floating roof tolerances within specified limits.
c) Floating roof seals properly fitted.
d) Shunts correctly installed, with continuity between roof and shoes.
e) Roof support legs adjusted to same specified height.
f) Roof drain lines and hoses properly connected and coiled on floor in accordance
with specified lay down pattern relative to roof legs.
g) Antirotation and centreing devices properly installed.
h) Emergency overflow protection correctly provided.
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4. Internal heaters or coolers properly supported and aligned.


5. Internal piping and mixers properly supported and aligned, with nuts suitably locked.
6. Fixed and rolling ladders installed properly, with rolling ladder in floating roof
monitored during hydrotesting for alignment and stability.
7. Internal tank gaging properly installed.
8. Foam injection or fire suppression system properly installed.
9. Final closure witnessed and accepted by BP or approved delegated authority.

15.1.2. Materials
a. Materials used in construction shall pass inspection following receipt at site.
b. Relevant certification shall be checked for compliance with material specification.
This is particularly important in case of material for tanks in refrigerated service.
Also see clause 9.8.

15.1.3. Foundations
a. Before erection, foundations shall be inspected, with finished top of foundation levels
checked for compliance with design.
b. See clause 19 for more detailed requirements on foundation testing and inspection.

15.1.4. Welding
Necessary requirements with regard to operations listed below shall comply with specifications,
subject to inspector approval (see clause 10 for further information):
a. Welder qualification.
b. Welding procedure qualification.
c. Plate alignment and nozzle fit ups.
d. Sequence in which joints are welded.
e. Stress relieving and PWHT, if applicable.
f. NDE, interpretation of results, and subsequent repair.
g. NDE technician qualifications, if not previously confirmed.

15.1.5. Erection
Following shall be checked as applicable to particular type of tank:
a. Baseline thickness, with checks performed before insulation application. Thickness shall
be recorded on approved BP forms.
b. Adequacy of protection of shell against wind damage during erection.
c. Positioning and orientation of nozzles and fittings.
d. Tank frangible roof weld joints in accordance with API Std 650.
e. Welding performed in accordance with approved welding sequence drawings.
f. Earthing (grounding) and bonding (clauses 22.1.13 or 23.1.13) installed in accordance with
project specifications.
g. Specified cathodic protection (clauses 22.1.19 or 23.1.19) and leak detection systems
properly installed.
h. Foam injection systems and fire suppression systems properly installed.
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i. Secondary containment system properly installed.


j. Platforms and stairways properly installed.
k. Insulation rings and clips correctly in place.
l. Instrumentation visible and accessible.
m. Piping connections and manways bolted up correctly.
n. Correct specification gaskets installed.
o. Holding down bolts correctly tightened or torqued.
p. Temporary attachments (e.g., dog clips and plate alignment brackets) removed and weld
deposits ground off (both internal and external).

15.1.6. Insulation, painting, and coatings or liners


a. External painting or coating, if applicable, shall be properly applied, with required DFT,
after hydrotest.
b. Internal coating or liners, if applicable, shall be properly applied, defect free, with
thickness in accordance with project specifications after hydrotest.
c. Insulation, if required, shall be installed after hydrotest (see clause 15.1.8.3).
d. Proper insulation material and thickness shall be verified (if required).
e. Following shall be properly installed and fitted (as applicable) to avoid water or water
vapour penetration:
1. Surface preparation.
2. Insulation.
3. Vapour barrier (for refrigerated service).
4. Jacketing.

15.1.7. Safety devices - preliminary


a. Before safety device installation, pressure and vacuum breakers shall be checked, tested,
and set in workshop.
See API 2000 for additional information.
b. Testing and setting shall be witnessed by inspector.

15.1.8. Testing

15.1.8.1. Scope
a. Test methods specified in design code for shell, floor plates (vacuum box test), roof, roof
drains, and heating coils shall comply with applicable test procedures (see clause 15.1.8.4).
b. Internal pipework shall be inspected and tested in accordance with clause 11.

15.1.8.2. Test medium


a. Fresh water shall be used for shell test.
b. For austenitic steel tanks, chloride content of test water shall not exceed 50 ppm.
c. For carbon steel tanks, if fresh water is not available in sufficient quantities:
1. Brackish or salt water may be used, subject to BP approval.
2. Immediately after testing, tank shall be washed down with fresh water to inspector
approval.
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See EEMUA 159 for additional guidance.

15.1.8.3. Pretest cleaning


a. Before testing, tank shall be cleaned and roof drains and heating coils shall be flushed to
inspector approval.
b. Testing shall be performed before painting or application of protective coating or
insulation.

15.1.8.4. Test procedures


a. Comprehensive test procedures shall be specified and agreed upon between BP and
Contractor.
b. Test procedure shall include:
1. Maximum filling rates.
2. Hold periods.
3. Normal and emergency emptying.
4. Method of measuring settlement.
5. Limits for differential and maximum settlement of foundations.
6. Minimum water temperature.
7. Water quality.
8. Need for inhibitors.
c. Test procedure as specified shall be rigorously followed.
d. Contractor measurements of settlement shall be witnessed and verified.
e. Inspector shall maintain independent record of settlement.
f. Particular care shall be taken during filling and emptying to ensure there is adequate
venting to avoid roof damage.
g. If inner and outer steel tanks of double or full containment liquefied gas tank are
hydrotested simultaneously, great care shall be taken with removal of water to prevent
damage to inner tank.
h. Liquid level in annular space shall always be kept equal to or lower than that of inner tank
to prevent compressive stresses in inner tank shell or bottom uplift.
i. Bottom insulation of inner tank shall be adequately protected against danger of liquid
penetration during testing.
j. Tanks shall be properly dried on test completion in accordance with specification.
See EEMUA 159 for additional guidance.

15.1.9. Tanks fabricated offsite


a. This clause covers inspection procedures for atmospheric tanks fabricated and tested in
Vendor facilities.
b. Inspection shall be performed in conjunction with clause 15.1.8.
c. Following shall be checked:
1. Tank shall comply in all respects with Vendor drawings and data sheet.
2. Before tank placement, foundation and structural support construction shall be
complete and shall comply with design drawings and specifications.

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3. Tank shall be initially inspected for transit damage.


4. After placement, tank shall be inspected for installation damage.
5. Pressure safety devices shall be correctly installed and shall be in certification.
6. Expansion end bolting shall be correctly installed.
7. If tank is included within piping pressure test pack, construction authority mechanical
engineer shall verify:
a) Existence on site of dedicated tank test certificate.
b) IRN is correct.
8. Before tank is authorised to be included in piping system test, piping system test
pressure shall be compared with tank pressure to ensure that pressure ranges are
compatible.
9. Tanks shall be certified in accordance with clause 15.2.4.

15.1.10. Tanks modified onsite


a. This clause covers inspection performed during onsite modification of tanks in addition to
inspection outlined in design specifications and drawings.
b. Inspection shall be performed in conjunction with clauses 15.1.1 and 15.1.8.
API 653 and EEMUA 159 also cover modification and repair of tanks.
c. Materials shall pass inspection on receipt at stores operated by BP or delegated authority.
d. Before tank is authorised for pressure testing, following inspection shall be performed:
1. NDE requirements, welding, and attachment welding shall be completed and
inspected in accordance with BP specification.
2. Stress relieving, if needed, shall be completed, with dedicated documentation
certifying completion made available.
3. Internal tank inspection shall ensure completion of works, with applicable
certification made available.
4. Tank shall comply with fabrication drawings and data sheets, with applicable and
correct fabrication records made available.
e. Inspection requirements in d. shall be verfied by construction authority mechanical
engineer.
f. After construction activities in tank modification have been completed and certified, tank
release authorisation shall be issued for pressure test with water or air (e.g., fixed roof test)
in accordance with agreed upon procedure.
g. Tank shall then be released for internal lining or painting and external insulation or
painting, during which further applicable inspection shall be performed.
h. Tank shall be recertified and stamped by certifying authority before being returned to
service, if so designated.
i. Tank certification shall comply with clause 15.2.4.

15.1.11. Certification
a. To record that checks and documentation are complete and that requirements of
clause 15.1 have been performed satisfactorily, following shall be completed by
construction authority and commissioning authority, as applicable, on approved Contractor
forms:

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1. Tank installation form (GOC form MV1).


2. Joint integrity certificate (GOC form JI1 Part A).

15.2. Commissioning

15.2.1. General
a. Commissioning shall incorporate functional energised testing of tank associated machinery
and operational system it exits (as applicable), including:
1. Heat exchangers.
2. Pressure and vacuum safety valves.
3. Controls (instruments, fire and gas).
4. Electrical components.
5. Leak testing.
6. Joint integrity certification.
b. Certification of interfaces shall be managed under appropriate discipline clause of this GP.
c. Before commissioning activities begin on system, following shall be completed and signed
off by construction and commissioning authorities on approved Contractor forms:
1. MC certificate (GOC form MC1).
2. Punch list (GOC form PL1).

15.2.2. Leak testing (tightness test)


a. Leak test shall be performed to ensure integrity of system before handover.
b. Leak test shall be performed on process and utility piping systems, equipment, and vessels.
c. Leak testing shall be performed in accordance with clause 11.2.3.

15.2.3. Joint integrity testing


a. See clause 11.1.6 for details on joint integrity testing.
b. For commissioning phase, following shall be completed:
1. Leak testing shall be performed in accordance with clause 11.2.3.
2. Data shall be recorded as to who witnessed leak test and leak test number for each
flange, threaded connection, gland, and packing.
If GOC form JI1 is being used, completion of Part A and B of form is required
before system handover certificate can be signed and equipment can be safely
operated.

15.2.4. Certification
a. To record that checks and documentation are complete and that requirements of
clause 15.2 have been performed satisfactorily, following shall be completed by
construction authority and commissioning authority, as applicable, on approved Contractor
forms:
1. Leak test certificate (GOC form SL1).
2. Joint integrity certificate (GOC form JI1 Part B).
b. Functional testing shall be documented on forms subject to BP approval.
c. Punch list items
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1. Punch list items shall be completed before tank is handed over to operations.
2. Exceptions shall be noted in exception report, subject to BP approval.

15.3. Post startup performance testing

15.3.1. General
a. After system handover, plant performance testing shall be performed to verify design
integrity, expectations, and that facility is performing to those expectations for agreed upon
time period.
b. See clause 27 for details.

15.3.2. Certification
See clause 27 for details of certification.

16. Machinery

16.1. Inspection and testing

16.1.1. General
a. Requirements of this clause apply to rotating and reciprocating machines and their drivers,
such as pumps, compressors, electric motors (other than for electrical inspection and tests),
steam and gas turbines, diesel and gas engines.
b. Requirements do not apply to small ancillary units (e.g., lube oil pump on larger machine,
refrigerant compressor motor unit in air conditioner, very small electric motors for
instruments and clocks).
c. Such equipment shall nevertheless be checked to ensure it is in proper working order.

16.1.2. Certification, preliminary inspection, and preservation


a. During storage and installation, inlet and outlet connections (e.g., main process and
service, lube oil, seal oil, cooling water) shall be blanked off to prevent ingress of dirt.
b. Vendor may be required to open machine for inspection and perform necessary remedial
cleaning at inspector discretion.
c. Machines shall be regularly hand or bar rotated throughout storage and post installation
periods to protect bearings. Frequency of this operation shall be obtained from Vendor.
d. Rotating record for each machine shall be maintained by Vendor and verified by inspector.

16.1.3. Foundations and supporting steelwork


Before machine is installed, concrete foundations and supporting steelwork shall be examined
and checked against erection drawings for dimensional accuracy.

16.1.4. Installation
Inspector shall witness/verify items in this clause for pumps, compressors, and skid mounted
units.

16.1.4.1. Miscellaneous
a. Pump, compressor, or skid unit shall:
1. Comply in all aspects with drawings and data sheets.

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2. Be installed to Vendor recommendations and engineering design installation


requirements.
3. Be free from mechanical damage and shall be internally clean.
b. Special installations
1. Special installation procedures specified by Vendor or BP shall be followed.
2. For large, complex, or highly specialised machines, Vendor may provide installation
engineer whose instructions shall be followed.
c. Interface points shall comply with Vendor drawings.
d. Painting and insulation
1. Painting, heat tracing, and insulation shall be complete and appropriate certificates
shall be approved.
2. Flanges shall be left uninsulated until after leak test.
e. Holding down bolts of skid unit, pump, compressor, and driver to baseplate and baseplate
to foundation or floor shall be correctly installed and tightened.
f. Unit shall be level, correctly shimmed, and fixed to base.
g. Before grouting:
1. Bedplate flatness, inclination to horizontal plane (measured in two mutually
perpendicular directions), and level (above datum) shall be verified.
2. Shaft alignment and end float shall be verified.
3. For reciprocating machines, crankshaft deflections shall be verified and recorded.

16.1.4.2. Grouting
a. Grouting material shall be:
1. Specified by Vendor.
2. Subject to BP approval.
3. Non shrinkable.
b. During grouting, adequate air vents shall be provided and grout properly vibrated to avoid
air entrapment, particularly in holding down bolt pockets.
c. Unless specified otherwise, fabricated box type bedplates shall be completely filled with
grout.
d. For large machines or machines with large out of balance forces, grouting may need to be
supervised by qualified representative of Vendor.
e. Grouting voids
1. After grout curing, bedplate top membrane shall be sounded to detect presence of
voids.
2. If voids are discovered, 3 mm (1/8 in) test hole shall be drilled in void area to
ascertain volume as preliminary assessment for possible remedial action.

16.1.4.3. Installation procedure


a. Initial alignment
1. Initial alignment shall be performed before primary process or service pipework is
connected, especially if machinery is on multiple independent baseplates (i.e., driver
and compressor).
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2. Other machinery with common baseplate is normally factory aligned.


3. Factory aligned machinery shall be field checked before piping installation at
discretion of inspector or rotating equipment engineer.
b. Machine frame bolting shall be checked for tightness to ensure that transit vibration has
not produced machine bolt slackness and to ensure that bolts comply with specification.
c. Piping
1. Piping shall be complete and correctly aligned.
2. Suction and discharge piping shall be completed with permanent pipe supports
installed, as applicable, and correctly aligned with correct gaskets installed.
3. Pipe strain induced on equipment shall not affect alignment more than 0,05 mm
(0,002 in) from 12:00 or 3:00 oclock dial indicator position.
4. Final alignment check shall be performed in commissioning phase.
d. Dissimilar metals isolation shall be achieved.
e. Ancillary systems, appurtenances, and enclosures (e.g., lube oil, seal oil, cooling water,
electrical, and control devices and trips) shall be complete and properly installed and
connected.
f. Drain and vent piping and valves (including bedplate drains) shall be connected and clear
of obstruction.
g. Mechanical seals shall be clean and completed.
h. Seal and lube oil systems shall be flushed correctly (pickled as necessary) and filled with
correct oil.
i. Access ladders and walkways shall be complete.
j. Weatherproof and noise attenuating enclosures (as required) shall be complete.
k. Bearings shall have correct lubrication.
l. Gearboxes and fluid couplings (as fitted) shall be filled with correct lubrication.
m. Instrumentation (including PSVs) shall be correctly fitted, visible, accessible for
maintenance purposes, and tested.
n. Temporary and permanent strainers shall be fitted and easily identified.
o. Rotating equipment shall be free to turn by hand.
p. Before coupling installation, driver shall be in correct direction of rotation.
q. Drive couplings, belts, and guards shall be correctly fitted.

16.1.4.4. Documentation
a. Approved Contractor machinery alignment form (GOC form MM2) shall be completed.
b. Mechanical punch list (GOC form PL1) shall be generated.
Refer to GIS 34-801 and project specific requirements for rotating equipment
(inspection, installation, and commissioning).

16.1.5. Skid mounted units


a. Skid mounted units generally consist of vessels, pumps, compressors, drivers, piping, and
instrumentation mounted on common frame or skid.
b. Larger equipment usually has two frames, one for driver and one for driven equipment.
c. Each discipline shall perform respective checks as required.
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d. Requirements in clause 16.1.4 shall be performed by construction authority mechanical


engineer, and results shall be recorded on approved Contractor mechanical installation
certificate (GOC form MM1).
e. Mechanical section of HCP shall typically contain following approved Contractor forms:
1. Mechanical installation certificate (GOC form MM1) for installation of skid unit.
2. Mechanical installation certificate (GOC form MM1) for each pump or compressor.
3. Machinery alignment certificate (GOC form MM2) for each pump or compressor and
associated driver.

16.1.6. Certification
To record that checks and documentation of installation of pumps, compressors, skid mounted
units, and other mechanical equipment are complete and that requirements of clause 16.1 have
been performed satisfactorily, following shall be completed by construction authority
mechanical engineer and signed off by BP rotating engineer or approved representative, as
applicable, on approved Contractor forms:
a. Mechanical installation certificate (GOC form MM1).
b. Joint integrity certificate (GOC form JI1 Part A). See clause 11.1.6.
Paint, insulation, and trace heating have not been included in this procedure, as
they are covered by certification under appropriate discipline clauses (i.e., painting,
coatings, and insulation or electrical) of this GP.

16.2. Commissioning

16.2.1. General
a. Commissioning shall incorporate functional energised testing of machinery and operational
system it exists (as applicable), including:
1. Heat exchangers.
2. Pressure and vacuum safety valves.
3. Controls (instruments, fire and gas).
4. Electrical components.
5. Machinery alignment.
6. Leak testing.
7. Joint integrity certification.
b. Certification of interfaces shall be managed under appropriate clause of this GP.
c. Before commissioning activities begin on system, following shall be completed and signed
off by construction and commissioning authorities on approved Contractor forms:
1. MC certificate (GOC form MC1).
2. Punch list (GOC form PL1).

16.2.2. Alignment

16.2.2.1. General
a. Special procedures
1. Special alignment procedures specified by Vendor or by BP shall be complied with
by Contractor.

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2. For large, complex, or highly specialised machines, Vendor may provide installation
engineer whose instructions shall be followed by Contractor.
b. Initial alignment
1. As mentioned in clause 16.1.4.3, initial alignment shall be performed before primary
process and service pipework is connected, especially if machinery is on multiple
independent baseplates (i.e., driver and compressor).
2. Other machinery with common baseplate is normally factory aligned.
3. Factory aligned machinery shall be field checked before piping installation at
discretion of inspector or rotating equipment engineer.
4. Trial pipework fit shall be performed before final alignment.
5. Satisfactory piping alignment shall be subject to inspector or rotating equipment
engineer approval.
c. Alignment
1. Alignment of driver to driven machine shall be performed after grout has adequately
cured.
2. General requirements for alignment are in clauses 16.2.2.2 through 16.2.2.8.
3. Alignment readings shall be recorded on approved Contractor machinery alignment
certificate (GOC form MM2).
4. Vendor specific alignment requirements shall take precedence over those specified in
clause 16.2.2.
5. Lasers may be used at discretion of inspector.
6. Couplings that are removed following alignment shall be properly marked or tagged
to ensure identification.
d. Alignment specifics
1. Procedures in clauses 16.2.2.2 through 16.2.2.8 shall be performed in conjunction
with approved Contractor machinery alignment certificate (GOC form MM2).
2. Other alignment procedures or deviations shall be subject to approval by BP rotating
equipment engineer or authorised representative.
3. Machinery shall have alignment checked by one of methods described in
clauses 16.2.2.3 through 16.2.2.5.
4. Tolerances shall be within Vendor standard requirements or 0,05 mm (0,002 in)
total indicated runout (TIR), whichever is less.
5. Shafts shall always be rotated in normal direction of rotation.
6. Readings shall be viewed from direction of driver to driven equipment.
7. Type of alignment procedure (e.g., rim and face, reverse, or optical) shall be entered
on approved Contractor machinery alignment certificate (GOC form MM2).
8. Target alignment to be achieved shall be entered in Required Alignment section of
certificate.
9. Freedom of movement
a) Equipment bearings shall be properly lubricated.
b) Before alignment, equipment shall be rotated by hand to verify freedom of
movement.

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10. Before alignment is performed, concentricity checks in clause 16.2.2.2 shall be


performed.

16.2.2.2. Concentricity checks and coupling hub runout


a. Setup
1. Two DTIs shall be mounted off shaft of driven machine, one on rim and one on face
of driver hub.
2. Pointers shall be placed in mid position and dials zeroed.
While taking face readings, ensure end float in shaft does not give inaccurate
readings. Push end float all one way.
b. Measurement
1. Driver hub shall be rotated at least twice in direction of rotation.
2. Actual rim and face runout shall be measured at 90 degree intervals.
3. Measurements shall be repeated for driven hub.
4. Readings shall be entered on approved Contractor mnachinery alignment certificate
(GOC form MM2).

16.2.2.3. Rim and face alignment


If GOC form MM2 is used for rim and face alignment, titles Driver Hub and
Driven Hub should be deleted, and titles Face and Rim inserted.
a. Rim alignment
1. DTI support bar shall be mounted on driver hub.
2. Pointer shall be placed in mid position on driven hub.
3. Dial shall be zeroed at TDC (e.g., 0 degrees).
4. Shaft shall be turned at least twice in direction of rotation.
5. Measurements shall be taken at 90 degree intervals.
6. Readings shall be entered on approved Contractor machinery alignment certificate
(GOC form MM2).
b. Face alignment
1. DTI shall be mounted between faces of driver and driven coupling hubs, ensuring that
shafts end float does not have any inaccuracies (i.e., push end float all one way).
2. Pointer shall be set in mid range and dial shall be zeroed.
3. Shaft shall be turned at least twice in direction of rotation.
4. Measurements shall be taken at 90 degree intervals.
5. Readings shall be entered on approved Contractor machinery alignment certificate
(GOC form MM2).

16.2.2.4. Reverse alignment


a. Setup
1. DTI offset supports shall be used to mount support for one DTI on driver hub and on
driven hub rim, one DTI on driven hub to driver hub.
2. Both DTIs shall be set mid range and both dials zeroed at TDC (0 degrees).
b. Measurement
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1. Both shafts shall be turned together in direction of rotation.


2. Measurements shall be simultaneously taken from both DTIs at 90 degree intervals.
3. Readings shall be entered on approved Contractor machinery alignment certificate
(GOC form MM2).

16.2.2.5. Optical alignment


a. Alignment shall be performed using optical Vendor alignment procedure.
b. Readings shall be entered on optical Vendor alignment sheet and attached to approved
Contractor machinery alignment certificate (GOC form MM2).

16.2.2.6. Distance between shaft ends


a. Internal micrometer or vernier calliper shall be used to check required distance between
shaft ends (DBSE) between driver and driven hubs.
b. Rotors for horizontal motors shall be set on magnetic centre before measuring and setting
DBSE.
c. Reading shall be entered on approved Contractor machinery alignment certificate (GOC
form MM2) taking into consideration end float in driver or driven equipment.

16.2.2.7. Soft footings


a. Both driven unit and driver shall be checked for soft foot condition.
b. With equipment finally aligned and hold down bolts properly torqued, two DTIs shall be
mounted from driver shaft to driven equipment coupling hub.
c. Indicators shall be positioned, one at 12:00 oclock and one at 3:00 oclock.
d. Driver hold down bolts shall be loosened one at a time and it shall be verified that neither
indicator moves more than 0,05 mm (0,002 in).
e. Step d. shall be repeated until all driver and driven equipment hold down bolts have been
checked.

16.2.2.8. Alignment certification


a. See clause 16.2.6.

16.2.3. Leak testing (tightness test)


a. Leak test shall be performed to ensure integrity of system before handover.
b. Leak test shall be performed on process and utility piping systems, equipment, and vessels.
c. Leak test shall be performed in accordance with clause 11.2.3.

16.2.4. Joint integrity testing


a. See clause 11.1.6 for details on joint integrity testing.
b. For commissioning phase, following shall be completed:
1. Leak testing shall be performed in accordance with clause 11.2.3.
2. For each flange, threaded connection, gland, and packing, data shall be recorded as to
who witnessed leak test and leak test number.
If GOC form JI1 is being used, completion of Part A and B of form is required
before system handover certificate can be signed and equipment can be safely
operated.

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16.2.5. Running (dynamic testing)

16.2.5.1. Preparation
a. Preparation and cleaning procedure before initial lubrication and requirements for packing
glands shall be performed, subject to inspector approval.
b. Mechanical seals, if fitted, shall have special inspection to ensure that ancillary pipework
and fittings are correctly installed.
c. Cleanliness of oil systems shall be based on applicable scale in ISO 4406.
d. Depreservation actions required to run machinery shall be performed.

16.2.5.2. No load running tests


a. No load running test procedures shall be agreed between BP and Vendor.
b. Vendor advice shall be obtained as necessary.
c. Agreed procedures shall be followed at all times, subject to inspector or rotating equipment
engineer approval.
d. Electric motors shall be checked for direction of rotation, generally in uncoupled
condition.
e. Certain units, such as fractional HP motors driving dosing pumps, shall not be uncoupled.
f. Drivers and ancillaries shall be run uncoupled at full operational speed at least 4 hours.
g. Driven equipment with auxiliaries shall be run at full operational speed, initially at no load,
at least 4 hours.
h. Bearing temperatures shall be monitored throughout test.
i. Test shall only be performed if equipment is not liable to suffer damage if run in test
condition.
Certain equipment (e.g., submersible pumps and dosing pumps) can only be safely
run dry for several seconds, and this would normally be performed for direction of
rotation check (see subclauses d. and e.).
j. If, for operational or other reasons, it is not possible to perform initial no load running test,
test shall be combined with performance test (see subclauses d. and e.).

16.2.5.3. Running tests


a. Pumps shall be run 24 hours with specified liquid introduced for this purpose.
b. Offshore platforms and facilities may be limited to shorter run times than onshore
facilities.
c. Strainers shall be opened for cleaning as required during test period.
d. Running tests on other types of machinery shall be as specified.

16.2.6. Certification
a. To record that checks and documentation of alignment of pumps, compressors, and other
mechanical equipment to interfacing equipment (motors, gears, turbines) are complete and
that requirements of clause 16.2 have been performed satisfactorily, following shall be
completed by construction authority and commissioning authority, as applicable, on
approved Contractor forms:
1. Machinery alignment certificate (GOC form MM2).

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a) Certificate shall be completed by person responsible for performing alignment


and shall be signed by BP rotating equipment engineer or approved
representative.Functional testing shall be documented on forms subject to BP
approval.
b) Certificate shall be completed and attached to Contractor mechanical installation
certificate (GOC form MM1). See clause 16.1.6.
2. Leak test certificate (GOC form SL1). See clause 16.2.3.
3. Joint integrity certificate (GOC form JI1 Part B). See clause 16.2.4.
b. Functional testing shall be documented on forms subject to BP approval.
c. Punch list items
1. Punch list items shall be completed before machinery or system is handed over to
operations.
2. Exceptions shall be noted in exception report, subject to BP approval.

16.3. Post startup performance testing

16.3.1. General
a. After system handover, plant performance testing shall be performed to verify design
integrity and expectations and that facility is performing to expectations for agreed upon
time period.
b. See clause 27 for details.

16.3.2. Certification
See clause 27 for details of certification.

17. Structural

17.1. Inspection and testing

17.1.1. General
Construction management responsibilities and associated quality planning for structural
activities is normally categorised and managed as follows:
a. Onsite
1. Construction authority shall be responsible for inspection and test activities and
management of construction Contractor who provides only labour and equipment.
2. Inspection and test activities specified to fulfil minimum quality control requirements
shall be clearly defined on inspection and test schedule (ITS).
3. Construction authority shall prepare, maintain, and issue reports that describe and
contain results of dimensional surveys performed onsite.
4. Flowcharts shall be developed to provide guidelines on handover of onsite work.
b. Offsite
1. Construction authority shall monitor performance of Management Contractor who is
directly responsible for fabrication and inspection and test activities.
2. Inspection and test activities performed by Managing Contractor that are deemed by
BP or delegated authority to be at critical stages in fabrication process and require

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witnessing before Contractor can proceed shall be clearly defined within Managing
Contractor QP or supplied ITS.
3. Construction authority shall monitor reports produced by fabricator offsite.
c. Acceptance of structural work is composite function of fabrication, NDE, and inspection
(clause 10), and painting, coatings and insulation services (clause 21).
d. Input by relevant discipline engineers is required in quality planning and subsequent
development of ITS for both offsite and onsite work.
e. Reporting and recording of inspection and acceptance of structural work shall be on
approved Contractor welding completion summary and structural completion certificate
(GOC forms MW1 and MS1), subject to BP or delegated authority approval.
f. Construction authority shall exercise sufficient dimensional control over work and shall
monitor or conduct surveys throughout prefabrication, fabrication, construction, and
installation stages to ensure that specified design tolerances are achieved.
g. Before installation, fabricator shall establish reference marks and levels required to assist
fit up.

17.1.2. Certification
a. Offsite structural acceptance
1. Approved Contractor structural completion certificate (GOC form MS1) shall certify
that offsite fabrication activities for discrete structure or component parts comply in
particulars with required design and that specified inspection and testing has been
completed and accepted.
2. Structural engineer authorised by BP shall categorise discrete structures into
following classifications for certification purposes:
a) Discrete structure (i.e., module, jacket, module support frame).
b) Assembly (i.e., module truss, jacket truss, deck extension).
c) Subassembly (i.e., truss node, tubular).
3. As minimum, subassemblies shall require approved Contractor structural completion
certificate (GOC form MS1) before they can be installed into assembly.
4. Assemblies shall require structural completion certificate before they can be installed
into discrete structure.
5. Discrete structures shall require structural completion certificate before they can be
released for shipment to onsite installation.
6. Structural completion certificate shall have following approved Contractor forms
attached, as appropriate:
a) Welding completion summary (GOC form MW1). See clause 10.
b) Final paint acceptance certificate (GOC AS1). See clause 21.
c) Architectural insulation/ coatings acceptance certificate (GOC form AS2). See
clause 21.
b. For onsite structural acceptance, structural completion certificate (GOC form MS1) shall
certify that:
1. Onsite activities relating to onsite fabrication and installation of structural work have
been completed and comply in particulars with approved design, fabrication, and
installation specifications.
2. Specified inspection and testing has been completed.
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3. Structural completion certificate shall have following approved Contractor forms


attached, as appropriate:
a) Welding completion summary (GOC form MW1). See clause 10.
b) Final paint acceptance certificate (GOC AS1). See clause 21.
c) Architectural insulation/ coatings acceptance certificate (GOC form AS2). See
clause 21.
c. If subsequent work creates concealed areas and prohibits further access for reinspection of
structural steel, construction authority shall note on structural completion certificate (GOC
form MS1) that concealed areas were inspected before concealment activity, such as
boxing in stiffeners or covering deck area or cladding.

18. Heating, ventilation, and air conditioning

18.1. Inspection and testing

18.1.1. Scope
This clause covers particular requirements for inspection and testing of HVAC.

18.1.2. Installation
a. Equipment and materials shall be inspected upon receipt onsite.
b. Remedial work performed on site by Vendor to correct transit damage or faulty
workmanship shall be supervised by construction authority.
c. Installation shall be supervised by construction authority.
d. Construction authority shall advise TI authority on completion of construction.
e. Inspections and tests that are to be recorded shall be subject to witnessing by TI authority.
f. Construction activities shall be monitored wherever possible by TI authority such that
inspection and testing can be performed as work proceeds.
g. Upon satisfactory completion of inspection and testing, construction authority shall sign
relevant records that shall be witnessed by TI authority as appropriate.
h. No further work shall be performed on completed plant without approval by TI authority.
i. Vendor assistance may be required during installation or commissioning of HVAC.
j. Testing of HVAC shall be witnessed by TI authority as appropriate.

18.1.3. General

18.1.3.1. Preliminary
Following shall be checked to ensure that overall system is in accordance with project
specifications and correctly installed before performing specific checks on individual parts of
installation:
a. Equipment shall be checked for damage.
b. Nameplate shall be in readable location, and data shall correspond with relevant equipment
index, specification, data sheet, and drawing with regard to identification, tag number,
ratings, and other data.
c. Equipment shall be installed in accordance with specifications, IFC drawings, and Vendor
instructions.

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d. Classification of locations where electrical equipment is installed shall be checked by


reference to area classification drawings to ensure that equipment installed in hazardous
locations (Zones 1 and 2 - eastern hemisphere and Class I, Division 1 - western
hemisphere) has appropriate certification.
e. Applicable installation procedures, inspections, and tests shall be performed for
mechanical, electrical and control equipment, compressors, fans, pumps, motors, cabling
switchgear, and instruments in accordance with this GP.
f. Earthing (grounding)
1. Equipment shall be properly earthed (grounded) and bonded in accordance with
drawings and specifications.
2. Ground path shall be measured and recorded.
3. See electrical specifications in clauses 22 (NEC) or 23 (IEC) as appropriate.
g. Painting
1. Painting shall be performed in accordance with project painting specification or
Vendor requirements.
2. Equipment shall be checked to verify that no damage has occurred during installation.
3. See clause 21 for further information.
h. Insulation
1. If thermal conservation and anticondensation are required, system shall be properly
insulated such that it meets project specifications and that no damage has occurred
during installation.
2. See clause 21 for further information.
i. Adequate space shall be provided to maintain and inspect equipment.
j. Equipment shall be internally and externally clean.
k. Items of noncompliance shall be noted, describing part of installation concerned and fully
identified on appropriate approved Contractor discipline punch list (GOC form PL1).

18.1.3.2. Inspection, test, and certification requirements


a. HVAC inspections, tests, and certifications as outlined in clauses 18.1.4 through 18.1.15
shall be properly recorded on approved forms by BP approved representative.
b. Each HVAC system shall have approved Contractor system performance test certificate
(GOC form SP2) and following additional forms attached:
1. System installation and function test certificate (GOC form TR1).
2. Fire damper tests (GOC form TR2).
3. Smoke test (GOC form TR16).
4. Room pressurisation test (GOC form TR17, Part 1).
c. Additional test data sheets
1. Additional test record sheets shall be completed and used as part of assessment
process to establish if HVAC system complies with design criteria.
2. After compliance has been established and Contractor system performance test
certificate (GOC form SP2) has been approved, other test records may be discarded
with exception of forms listed in subclause b.
d. Approval certificate

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1. Approved Contractor system performance test certificate (GOC form SP2) shall be
completed by BP HVAC commissioning representative or Vendor as appropriate.
2. Certificate shall indicate that necessary inspections and tests have been performed
satisfactorily in accordance with HVAC inspections and tests in clause 18, within
design and operating parameters, and in accordance with Vendor instructions.
3. Variances shall be detailed on appropriate test record sheet and attached to certificate.

18.1.3.3. Test equipment calibration requirements


Test equipment used in commissioning of HVAC systems, whether in house or Vendor
supplied, shall have current calibration certificate stating that test equipment has been calibrated
to specified limits within specified time span.

18.1.4. Dampers

18.1.4.1. General
a. TI authority may require additional tests for fire dampers.
b. Following items shall be checked and tested to ensure that dampers in HVAC system
comply with project specifications and are correctly certified and installed:
1. Relevant checks in clause 18.1.3 shall be performed.
2. Access doors adjacent to dampers shall be installed as applicable.
3. Damper blade clearance and sealing shall be satisfactory.
4. Damper blades shall move freely.
5. Blade position external indicator shall be fitted and shall give correct indication.
6. Blade position locking quadrant shall be satisfactory.
7. Movement of damper shall correspond to specified type of control.
8. Damper shall be properly lubricated, as applicable.
9. If damper width exceeds 1 m (40 in), damper blades shall be adequately supported.
10. Blades shall be enclosed in casing with damper in fully open position.
11. Damper actuators shall be free to move and shall be suitably enclosed.
12. Damper controls shall move freely and shall be unobstructed for routine maintenance
and periodic certification inspection.
13. Local hand lever shall move freely.
14. Damper shall be adequately supported.
15. Correct gaskets shall be fitted to connecting ductwork.
16. Damper shall be bolted correctly.
17. Dissimilar metals shall be properly isolated.
18. Integrity of bulkhead penetration shall be maintained as required, and penetration
shall be properly sealed with fire stopping.
19. Tension spring shall be fitted, and there shall be adequate space through enclosure
access plate to maintain tension spring adjustment for pressure setting.
20. Damper shall be internally clean and shall be left in fully open position.
21. Access cover to enclosure shall be reinstalled.
22. If damper is mechanically stroked, limit switches shall operate to make and break.
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23. Instrument air supply tubing and piping shall be correctly fitted and shall function
correctly.
24. Mechanical reset mechanism shall reopen electric dampers.
25. Fusible link of correct rating shall be fitted and shall be accessible, and damper shall
close and seal correctly.
Caution: Dampers are typically spring loaded and rapid closing!
26. Insulation
a) Insulation shall be fire rated as specified.
b) Insulation shall be correctly fitted after ensuring that damper material and finish
are as specified and undamaged.
27. Fire dampers shall have appropriate fire resistance test certificates and UL or NRTL
listing and label.
28. As appropriate, dampers shall have TI authority certification.

18.1.4.2. Damper test and certification


a. Applicable inspection and test data results shall be recorded on approved Contractor
damper test form (GOC form TR2) by authorised BP representative.
b. Tests relevant to damper type in clauses 18.1.3 and 18.1.4.1 shall be performed
satisfactorily.
c. Deviations to design or operating parameters and Vendor instructions shall be noted on
report.

18.1.5. Filtration

18.1.5.1. General
Following shall be checked or tested, as appropriate to equipment type, to ensure that air filters
and filter coalescers comply with project specifications and are correctly installed:
a. Relevant checks in clause 18.1.3 shall be performed.
b. Equipment shall be properly supported and bolted.
c. Correctly specified gaskets shall be fitted to connecting ductwork.
d. Dissimilar metals shall be properly isolated.
e. Filter elements and removal guide rails shall be properly installed, and adequate space
shall be provided to maintain and remove filters.
f. Access doors adjacent to unit shall be properly installed, as applicable.
g. Differential pressure indicator shall be in readable position, and associated pipework shall
be correctly installed.
h. Spray nozzles shall be clean.
i. Drain connections and traps shall be correctly located, shall be free of blockage and
restrictions, and traps may be visually checked for water level.
j. Heat trace, if required, shall be installed and inspected in accordance with relevant
electrical procedures in clause 22 (NEC) or clause 23 (IEC).

18.1.5.2. Filter, coalescer, and separator test and certification


a. Appropriate inspection and test data results shall be recorded on approved Contractor filter,
coalescer, and separator test forms (GOC form TR3) by authorised BP representative.
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Forms certify that equipment has performed satisfactorily in accordance with


clauses 18.1.3 and 18.1.5.1.
b. Deviation to design and operating parameters or Vendor instructions shall be noted on
report.

18.1.6. Heating and cooling coils

18.1.6.1. General
Following shall be checked or tested as appropriate to equipment to ensure that heating and
cooling coils comply with project specifications and are correctly installed:
a. Relevant checks in clause 18.1.3 shall be performed.
b. Heating and cooling coils shall be adequately supported and properly bolted and fixed.
c. Correct specification gaskets shall be fitted to connection ductwork.
d. Dissimilar metals shall be properly isolated.
e. Heating elements shall be clean, undamaged, and readily accessible, with adequate space
provided for element withdrawal and maintenance.
f. Cooling coil shall be correctly installed and undamaged.
g. Unit shall be level and complete with guide rails to slide coil from holding frame, with
adequate space provided for coil withdrawal.
h. High air temperature and high element temperature cutout thermostats shall be correct type
and accessible for resetting and maintenance, as applicable.
i. Electrical
1. Electrical connections to heater shall be correctly terminated.
2. Cables shall be inspected and tested in accordance with electrical procedures in
clause 22 (NEC) or 23 (IEC).
3. Terminal box access cover shall be readily accessible.
j. Access cover shall be properly installed in ductwork adjacent to heater.
k. Distributors and pipework shall be correctly connected and interior connections clean.
l. Drain pan shall be correctly fitted, and if coil is split vertically, both sections shall have
drain pans.
m. Float level shutoff switch to prevent drain pan overflow.
n. Interconnecting pipework between upper and lower drain pans shall be correctly installed
and drain trap correctly fitted with pipework routed to suitable discharge.
o. Air venting facility, if applicable, shall be correctly installed.

18.1.6.2. Heating and cooling coil tests and certification


a. Results of applicable inspection and testing shall be recorded on approved Contractor
heating and cooling coil test forms (GOC form TR4) by authorised BP representative to
certify that equipment complies with clauses 18.1.3 and 18.1.6.1.
b. Deviations to design and operating parameters or Vendor instructions shall be noted on
report.

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18.1.7. Centrifugal fans and drivers

18.1.7.1. General
Following shall be checked or tested as appropriate to ensure that centrifugal fans and drivers
comply with project specifications and correctly installed:
a. Relevant checks in clause 18.1.3 shall be performed.
b. Fan assembly shall be adequately supported and properly bolted.
c. Correct specification gaskets shall be fitted to connecting ductwork.
d. Dissimilar metals shall be properly isolated.
e. Fan and motor shall be correctly mounted in right angular position.
f. Motor shall be level and aligned with specified drive fitted.
g. Motor shall be inspected in accordance with electrical procedures in clause 22 (NEC) or 23
(IEC).
h. Vibration isolators shall be installed and correctly adjusted for specified deflection.
i. Shipping locks shall be removed.
j. Inlet and outlet flexible connections shall be correctly fitted and shall not take up offsets.
k. Internal shipping brackets or packings shall be removed.
l. Fan shall be internally and externally clean.
m. Fan and motor bearings shall be properly lubricated and grease nipples shall be accessible.
n. Fan belt drive guard shall be removed to visually check fan shaft level and bearing
alignment, then guard shall be replaced.
o. Belts shall be correctly tensioned.
p. Fan impeller shall freely rotate. Key shall be secure and shall have satisfactory clearance.
q. Adequate space shall be provided to withdraw impeller or motor assembly for
maintenance.
r. Fan belt guard shall be lined with nonferrous material.
s. Fan guards shall be securely fitted.
t. Manually operated inlet guide vane control damper shall be correctly fitted and shall be
inspected in accordance with clause 18.1.4.
u. Outlet non return damper shall be correctly fitted and shall be inspected in accordance with
clause 18.1.4.
v. Direction of rotation shall be correct.
w. Air Movement and Control Association (AMCA) Standard 99-0401 Type B Spark Class
for non sparking construction shall be verified, as applicable.
x. Contact between moving and stationary parts or rubbing of parts shall not be possible.

18.1.7.2. Centrifugal fans and drivers test and certification


a. Results of applicable inspections and tests shall be recorded on approved Contractor
centrifugal fans and drivers test forms (GOC form TR5) by BP approved HVAC
representative to certify that equipment has performed satisfactorily in compliance with
clauses 18.1.3 and 18.1.7.1.
b. Deviations to design and operating parameters or Vendor instructions shall be noted on
report.
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18.1.8. Humidifiers

18.1.8.1. General
Following shall be checked or tested, as applicable, to ensure that humidifiers comply with
project specifications and are correctly installed:
a. Relevant checks in clause 18.1.3 shall be performed.
b. Humidifier and steam injection duct shall be properly mounted and adequately supported.
c. Steam injection duct shall be installed in accordance with Vendor recommendations.
d. Steam injection duct shall drain back to humidifier.
e. Ductwork shall be correctly bolted and flanged connections shall have correct gaskets
fitted.
f. Balance pipe from humidifier to ductwork shall be installed and properly sealed.
g. Utility pipework connections to humidifier shall be correctly installed and adequately
supported.
h. Water inlet valve shall be properly fitted and shall operate correctly.
i. Drain and overflow shall be correctly fitted and piped to suitable drain.
j. There shall be adequate space to maintain humidifier internals (e.g., water storage tank and
steaming chamber).
k. Heating elements shall be clean, undamaged, and readily accessible.
l. Water and heater thermostats shall be properly fitted in humidifier integral electrical
compartment with removable access cover provided.
m. Water level in storage tank shall be correct and level gage shall indicate correctly.
n. Adjacent ductwork connections and traps shall be correctly located, free of blockages and
restrictions, and traps can be visually checked for water level.
o. Humidifiers shall be operable for duct pressure (water lock).

18.1.8.2. Humidifier test and certification


a. Results of appropriate inspection and tests shall be recorded on approved Contractor
humidifier test forms (GOC form TR6) by BP authorised HVAC representative to certify
that equipment complies with clauses 18.1.3 and 18.1.8.1.
b. Deviation to design and operating parameters or Vendor instructions shall be noted on
report.

18.1.9. Constant volume terminal reheat units, grills, and diffusers

18.1.9.1. General
Following shall be checked or tested as applicable to ensure that terminal units, grilles, and
diffusers comply with project specifications and are correctly installed:
a. Relevant checks in clause 18.1.3 shall be performed.
b. Terminal reheat unit shall be properly aligned, adequately supported, and components shall
be correctly bolted or fixed.
c. Correct specification gaskets shall be fitted to connecting ductwork.
d. Dissimilar metals shall be properly isolated.

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e. Valve linkage mechanism shall have free movement and shall be preset for correct
pressure drop rating.
f. Valve mechanisms shall be properly lubricated.
g. There shall be adequate space to maintain constant volume control valve through access
cover to damper section.
h. Internal acoustic lining to prevent noise breakout shall be correctly installed.
i. Heating elements shall be undamaged, readily accessible, and shall have adequate space
for element withdrawal or maintenance.
j. High air temperature and high element temperature cutout thermostats shall be accessible
for resetting or maintenance.
k. Unit shall be internally clean and free from moisture.

18.1.9.2. Constant volume terminal reheat units, grilles, and diffusers test and certification
a. Results of applicable inspection and tests shall be recorded on approved Contractor
constant volume terminal reheat units, grilles, and diffusers test forms (GOC forms TR7
and TR12) by BP authorised HVAC representative to certify that equipment complies with
clauses 18.1.3 and 18.1.9.1.
b. Deviations to design and operating parameters or Vendor instructions shall be noted on
report.

18.1.10. Air conditioning units

18.1.10.1. General
Following shall be checked or tested as applicable to ensure that air conditioning units comply
with specifications and are correctly installed:
a. Relevant checks in clause 18.1.3 shall be performed.
b. Unit shall be adequately supported and bolted.
c. Correct specification gaskets shall be fitted to connecting ductwork.
d. Dissimilar metals shall be properly isolated.
e. Fans and compressors shall be correctly installed, with reference to clause 18.1.7 (for
compressors, substitute compressor for fan).
f. Filters shall be correctly installed, with reference to clause 18.1.5.
g. Pipework connections shall be correct and adequately supported.
h. Drain pan and drain pipes shall be correctly installed, with drains routed to suitable
location.
i. Float level cutoff switch to prevent drain pan overflow.
j. Inspection doors, hatches, and locks shall be operable.
k. Valves shall be operable.
l. Insulation shall be installed to specification, correctly fitted, and free of damage.
m. Refrigeration charge shall be within specifications.

18.1.10.2. Terminal air conditioning unit test and certification


a. Results of applicable inspection and tests shall be recorded on approved Contractor
terminal air conditioning unit test form (GOC form TR8) by authorised BP HVAC
representative to certify that equipment complies with clauses 18.1.3 and 18.1.10.1.
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b. Deviations to design and operating parameters or Vendor instructions shall be noted on


report.

18.1.11. Air handling unit

18.1.11.1. General
Following shall be checked or tested as applicable to ensure that air handling units comply with
project specifications and are correctly installed:
a. Relevant checks in clause 18.1.3 shall be performed.
b. Air handling units skid base holding down arrangement shall be correct.
c. Components shall be properly fitted together.
d. Dissimilar metals shall be properly isolated.
e. Equipment installed within air handling unit shall be checked against following
procedures:
1. Fans: clause 18.1.7.
2. Shutoff dampers: clause 18.1.4.
3. Heating and cooling coils: clause 18.1.6.
4. Filters: clause 18.1.5.
f. Ductwork connections to unit shall have correct specification gasket fitted.
g. Compartment sections shall have light fixtures as indicated in project specification.
h. Cabling and fittings shall be tested and inspected in accordance with applicable electrical
procedures.
i. Individual equipment compartments shall have inspection and access doors with proper
handles, catches, and locks which are operable.

18.1.11.2. Air handling unit test and certification


a. Results of applicable inspection and tests shall be recorded on approved Contractor air
handling unit test form (GOC form TR9) by BP authorised HVAC representative to certify
that equipment complies with clause 18.1.11.1.
b. Deviations to design and operating parameters or Vendor instructions shall be noted on
report.

18.1.12. Ductwork

18.1.12.1. General
Following shall be checked or tested as applicable to ensure that system ductwork complies with
project specifications and is correctly installed:
a. Relevant checks in clause 18.1.3 shall be performed.
b. Ductwork systems shall be clearly identified and correctly marked with directional flow
arrows.
c. Ductwork system shall be installed in compliance with P&ID layout and specifications.
d. Flexible connections shall be correctly fitted and sealed.
e. Flexible connection shall not be used to take up misalignment between sections of
ductwork or connections to plant equipment.
f. Correct jointing and sealants shall be used in accordance with project specification.
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g. Flanged ductwork joints shall be correctly bolted.


h. Correct specification gaskets shall be fitted.
i. Ductwork doors, panels, and hatches shall be correctly located and properly fastened and
sealed.
j. If access doors are installed in ductwork above false ceiling, ceiling shall have adequate
access.
k. Stiffening and turning vanes shall be correctly installed.
l. Instrument test holes shall be drilled and suitably plugged.
m. Ductwork shall be correctly supported and insulated from supports.
n. Supply ductwork shall have proper insulator blocks.
o. Dissimilar metals shall be properly isolated.
p. Diffusers and grilles shall be correctly installed and sealed, with diffusers and grilles and
associated volume control dampers left in open position.
q. Intake and discharge louvers shall be correctly installed, with necessary bird mesh
protection screens fitted.
r. Ductwork systems shall be internally clean and with no internal damage.
s. Air filter racks shall be properly fitted.
t. Fire dampers shall be installed in correct location, with correct fusible links fitted.
u. Filter or coalescer shall be loaded, separators shall be clean, drains shall be piped, and
traps shall be functioning.
v. Sound attenuators shall be correctly installed.
w. Protective coatings and finish of ducting shall comply with project specifications and shall
be undamaged.
x. Ductwork systems shall be leak tested in accordance with HVAC test classes in project
specifications and clause 18.1.5.
y. Ductwork shall be insulated in accordance with project specifications.
z. External insulation shall be applied only after ensuring that duct leakage rate test certificate
has been accepted and signed.
aa. Marked up drawings shall be produced that are in accordance with installation.

18.1.12.2. Ductwork test and certification


a. Results of applicable inspection and tests shall be recorded on approved Contractor system
performance test form (GOC form SP2) by BP authorised representative to certify
ductwork complies with clauses 18.1.3 and 18.1.12.1.
b. Deviations to design and operating parameters or Vendor instructions shall be noted on
report.

18.1.13. Sound attenuators

18.1.13.1. General
Following shall be checked or tested as applicable to ensure that sound attenuators comply with
project specifications and are correctly installed:
a. Relevant checks in clause 18.1.3 shall be performed.

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b. Sound attenuator location and orientation shall be correct, with unit installed for correct air
flow direction.
c. Sound attenuator shall be adequately supported and correctly bolted.
d. Correct specification gaskets shall be fitted.
e. Dissimilar metals shall be properly isolated.
f. Sound attenuator shall be internally clean, with no damage to acoustic lining or splitters.
g. No moisture shall have entered unit.
h. Fire and thermal insulation shall be correctly fitted.
i. Sound attenuator material and finish shall be correct to specification.
j. No damage shall have occurred during installation.
k. Installation configuration shall comply with Vendor instructions and airflow direction.

18.1.13.2. Sound attenuator test and certification


a. Results of applicable inspection and tests shall be recorded on approved Contractor system
performance test form (GOC form SP2) by authorised BP HVAC representative to certify
that sound attenuators comply with clauses 18.1.3 and 18.1.13.1.
b. Deviations to design and operating parameters or Vendor instructions shall be noted on
report.

18.1.14. Cooling towers

18.1.14.1. General
Following shall be checked or tested as applicable to ensure that cooling towers comply with
project specifications and are correctly installed:
a. Relevant checks in clause 18.1.3 shall be performed.
b. For fan section, relevant checks in clause 18.1.7 shall be performed.
c. For coil section, spray nozzles shall be clean and eliminators shall be undamaged.
d. For pan section, immersion heater shall be installed and undamaged.
e. Spray pump shall be aligned and rotation shall be correct.
f. Water level shall be correct.
g. Bleed line shall be operational.
h. Strainer shall be clean.
i. Corrosion inhibitor shall be properly installed.
j. Water makeup valve shall be open and float shall be operational.

18.1.14.2. Cooling tower test and certification


a. Test recording sheet (GOC form TR11) shall be used to provide collation of cooling tower
test data to enable subsequent signing of applicable part of system performance test
certificate (GOC form SP2).
b. Results of applicable inspection and tests shall be recorded on approved Contractor system
performance test form (GOC form SP2) by authorised BP HVAC representative to certify
that cooling towers complied with clauses 18.1.3 and 18.1.14.1.
c. Deviation to design and operating parameters or Vendor instructions shall be noted on
report.
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18.1.14.3. Pipework test and certification


a. Associated pipework shall be fabricated, inspected, and tested in accordance with project
specification and reference to pipe testing in clause 11.1.5.
b. Deviations shall be noted on report.

18.1.15. Areas receiving HVAC


a. HVAC tests in this clause shall be performed by HVAC Vendor or engineer and results
shall be recorded to ensure that applicable inspections and tests have been performed.
b. Deviation to design and operating parameters or Vendor instructions shall be recorded on
appropriate test record forms.
c. Test results shall be recorded on approved Contractor forms by authorised BP
representative to enable subsequent signing of applicable part of HVAC system
performance test certificate (GOC form SP2) for following:
1. For ductwork leakage rate test (GOC form TR13).
2. For system balance test (GOC form TR14).
3. For grille and diffuser test (GOC form TR12).
4. For internal conditions test (GOC form TR15).
5. For smoke test of pressurised rooms and areas protected by gaseous inerting agent
(GOC form TR16).
6. For room pressurisation test (GOC form TR17).
7. For room pressurisation unit test (GOC form TR18).

19. Civil inspection and testing

19.1. General
a. Scope of civil construction covers civil and buildings (architecture) activities in general
and may not be applicable to all project activities.
b. Applicable requirements of this clause shall be included within civil or architectural
inspections and acceptance produced by construction authority.
c. Onsite and offsite activities and operations shall be planned and performed in accordance
with agreed upon procedures.
d. Agreed upon procedures shall define sequence, methods, controls, criteria for acceptance,
inspection and testing, recording of test results, and evaluation.
e. Frequency of tests shall take into account consistency of test results and changes in
characteristics.

19.2. Civil work

19.2.1. Scope
a. Civil work scope as defined by contract drawings shall be divided into discrete civil
construction work packages.
b. Each work package shall cover civil works within specified area of site and be clearly
identified on applicable drawings.
c. Work package may be further subdivided for convenience of site inspection and testing.

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d. Construction authority shall be responsible for generating and documenting requests for
inspection, certificates, and necessary supporting documentation before submitting to BP
for approval.

19.2.2. General
Construction management responsibilities and associated quality planning for civil activities
shall normally be categorised and managed as follows:
a. Onsite
1. Construction authority shall be responsible for I&T activities and management of
Construction Contractor who provides only labour and equipment.
2. I&T activities shall be clearly defined on specified ITS for work to be performed and
recorded to fulfil minimum quality control requirements.
3. Construction authority shall prepare, maintain, issue, and monitor reports that
describe extent and contain results of dimensional surveys performed onsite.
4. Flowcharts shall be developed to provide guidelines on handover of onsite work.
b. Offsite
1. Construction authority shall monitor performance of Management Contractor who is
directly responsible for fabrication and I&T activities.
2. I&T activities performed by Management Contractor that are deemed by BP to be at
critical stages in fabrication process and require witnessing before Contractor can
proceed shall be clearly defined within Managing Contractor QP or supplied ITS.
c. Acceptance of structural works is composite function of fabrication and inspection (see
clause 17).
d. Input from relevant discipline engineer is required in quality planning and subsequent
development of ITS for both offsite and onsite work.
e. Reporting and recording of inspection and acceptance of civil work shall be on Contractor
standard forms (GOC forms CW1, CW2, CW3, CW4, CW5, and CW6) and shall be
subject to BP approval.
f. Construction authority shall exercise sufficient dimensional control over civil work and
shall monitor or conduct surveys throughout prefabrication, fabrication, construction, and
installation to ensure that specified design tolerances are achieved.
g. Contractor shall establish reference marks and levels before installation.
h. Construction authority shall ensure that applicable permits are obtained and approved,
including Area Civil Work Requests (ACWR), and Tundra Access Permits and U.S. Civil
Corp. of Engineers Gravel Placement Permits. General source shall be approved and
permitted pit.

19.2.3. Soils and earthwork


a. Control of soils and earthwork operations shall ensure that site subgrade is prepared
suitably free of extraneous materials, voids, and excess moisture, and that fill operations
are not performed in inclement weather.
b. Soil compaction activities shall be performed such that fill material shall not separate if:
1. Applied and spread in accordance with specified lift thickness.
2. Appropriate watering and compaction is performed.
c. Appropriate tests for compaction, grain size, plasticity, and field density shall be
performed during construction.
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d. Construction authority civil engineer shall ensure that frequency of tests is dependent upon
consistency of results and changes in material characteristics.

19.2.4. Piling operations


a. Piling operations shall be subject to controls and inspections that ensure that type, location,
and position of piles are verified, and pile hammer, cushion material, and driving
procedure and sequence are adequately described and recorded.
b. Construction authority civil engineer shall ensure that suitable record of number of pile
driving strokes for each pile is maintained.
c. Cast in piles shall be checked to confirm that alignment is correct.

19.2.5. Concrete
a. Site control
1. Site control procedures shall ensure that adequate inspection and testing for all
aspects of concrete construction are performed.
2. Extent of control shall be dependent upon structural function of concrete structure.
b. Material storage
1. Controls employed for material storage and handling techniques shall ensure that:
a) Cement storage facilities are suitably weather tight.
b) Type and age of cement is verified.
2. Aggregate stockpiles shall be inspected to ensure temperature and moisture controls
are in operation and that storage and handling techniques prevent contamination.
3. Admix storage and handling facilities shall be inspected to verify that deterioration
and contamination are prevented.
4. Inspections shall include water quality and concrete temperatures.
c. Mixing
1. Measuring and mixing operations shall be monitored to ensure cement, water, and
aggregate proportions are checked and recorded.
2. Aggregate moisture compensation measures, mixing time, and temperature controls
shall be verified.
d. Placement
1. Inspections shall be performed before concrete placement to confirm that location and
configuration of formwork and size, orientation, and installation of reinforcing steel is
correct.
2. Placement operations shall be monitored to ensure that preparations are checked to
confirm that specified material has been used and condition of material, gradation,
and compaction are correct.
3. Concrete placement inspection shall confirm that specified testing of concrete is
performed and adequate concrete consolidation equipment and techniques are used.
4. Appropriate cube or cylinder testing shall be performed and results shall berecorded.
e. Voids or contamination
1. Finished construction shall be inspected to check for voids or contamination.
2. If considered necessary by construction authority civil engineer, concrete may need to
be physically removed to determine extent of voids or contamination.
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19.3. Steel construction


a. Steel construction, including related items, such as anchor bolts and base plates forming
part of supporting structure, shall be inspected at appropriate stages of construction.
b. Anchor bolts and base plates shall be checked for correct type, location, orientation, and
bolt hole alignment prior to erection.

19.4. Piping
Requirements of this clause apply to pipework within scope of GP 04-10.
a. Piping activities associated with civil work shall be subject to controls and inspections that
ensure location and construction methods adopted.
b. Metallic pipe testing shall comply with clause 11.1.5.
c. Work shall be performed in accordance with procedures that adequately take account of
complexity, uniqueness, or novelty of item, and need for special controls or surveillance
over processes, methods, or equipment.
d. Particular attention shall be made to ensure laying, jointing, and backfill operations do not
jeopardise integrity of nonmetallic piping.

19.5. Certification

19.5.1. Civil acceptance


a. Offsite civil acceptance
1. Approved and completed Contractor civil completion certificate (GOC form CW6)
shall certify that offsite fabrication activities for discrete structure or component parts
complies with design requirements and that specified inspection and testing is
completed and accepted.
2. As minimum, subassemblies shall require civil completion certificate (GOC form
CW6) before installation into assembly.
3. Assemblies shall require civil completion certificate (GOC form CW6) before
installation into discrete structure.
4. Discrete structures shall require civil completion certificate (GOC form CW6) before
they can be released for shipment onsite for installation.
b. For onsite civil acceptance, approved and completed Contractor civil completion certificate
(GOC form CW6) shall certify that:
1. Onsite activities relating to onsite fabrication and installation of civil work have been
completed and comply with approved design, fabrication, and installation
specifications.
2. Specified inspection and testing is completed and accepted.
c. Concealed or covered work
1. If subsequent work will prohibit further access, items of work concealed in finished
work (underground or by closure or as result of gravel installation, covering filler
fabric, drainage structures, or other work) shall be inspected immediately before
being covered or concealed.
2. Inspection and testing shall be recorded on approved Contractor civil completion
certificate (GOC form CW6) to clearly identify area that was inspected before
covering.

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3. As built drawing data shall also be recorded and relevant coordinates shall be
confirmed.
d. Protective coatings
1. Painting or other coating of items or surfaces for which coating is essential to
preservation of item quality, including safety (e.g., PFP), shall be performed and
inspected in accordance with approved procedures.
2. Refer to final coating and insulation certificate (GOC form AS2) as detailed in
clause 21.

19.5.2. Civil work

19.5.2.1. General
a. Civil work shall be accepted by using forms listed in clauses 19.5.2.2 and 19.5.2.3.
b. Forms may be GOC forms or Contractor forms, subject to BP approval.
c. Construction authority shall use its own suite of forms to record piling activities.
d. Construction authority civil engineer shall record acceptance on forms in c. that will form
part of permanent record documents.

19.5.2.2. Civil work inspection certificates


a. Reinforced concrete
1. Approved Contractor reinforced concrete works certificate (GOC form CW1) shall
provide inspection checklist to record that works referenced have been inspected at
various stages of construction and that work complies with contract requirements and
project design criteria, drawings, and specifications.
2. Incomplete work shall be detailed on punch list (GOC form PL1).
b. Underground services and drainage
1. Approved Contractor underground services and drainage certificate (GOC form
CW2) shall provide inspection checklist to record that works referenced have been
inspected at various stages of construction and that work complies with contract
requirements and project design criteria, drawings, and specifications.
2. Service function, size, and type of pipe or drain, jointing or fittings, and manhole or
gully shall be recorded on certificate.
3. Incomplete work shall be detailed on punch list (GOC form PL1).
c. Earthworks, roads, and flexible paving
1. Approved Contractor earthworks, roads, and flexible paving certificate (GOC form
CW3) shall provide inspection checklist to record that works referenced have been
inspected at various stages of construction and that work complies with contract
requirements and project design criteria, drawings, and specifications.
2. Incomplete work shall be detailed on punch list (GOC form PL1).
d. Transportation and concrete placement
1. Approved Contractor transportation and concrete placement certificate (GOC form
CW4) shall provide inspection checklist to record that works have been inspected and
work complies with contract requirements and project design criteria, drawings, and
specifications.
2. Concrete data, such as mix, grade and description, quantity, ticket or truck number,
loading and delivery time, shall be recorded on certificate.
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3. Incomplete work shall be detailed on punch list (GOC form PL1).


e. Approved Contractor concrete test cube and cylinder summary certificate (GOC form
CW5) shall be used as summary record sheet for concrete testing results.

19.5.2.3. Civil construction completion certificate


a. Approved Contractor civil construction completion certificate (GOC form CW6) shall be
used for acceptance of onsite and offsite work, assemblies, subassemblies, or discrete
structures and acceptance of areas or sub areas that are required to be handed over and
made available to another Contractor.
b. Civil construction completion certificate shall only be accepted after relevant supporting
documentation is available and accepted.
c. Acceptance of civil construction completion certificate by construction authority,
commissioning authority, or OA shall only confirm that area or collective areas are ready
for system handover (GOC form SH1).
d. Acceptance of civil construction completion certificate on its own shall not constitute
system handover or operator acceptance.

19.6. Buildings, fittings, and furnishings (architectural)

19.6.1. General
a. Requirements of this procedure shall apply to architectural acceptance of areas used as
permanent offices, control rooms, laboratories, or rest rooms.
b. Requirements shall be included in any procedure for inspection and acceptance of
architectural works produced by construction authority.
c. Acceptance of associated services (e.g., fire and gas detection, electrical power and
lighting, and HVAC) is contained in relevant clauses of this GP.
d. Inspection of areas shall be performed after installation of all items and completion of
testing of services and utilities to area by appropriate disciplines.
e. Overall standard of workmanship of areas shall be considered in addition to minimum
inspection points.
f. Control rooms
1. In control rooms, completion activities normally continue until final handover to
operator.
2. Handover program shall be agreed upon between construction authority,
commissioning authority, and operations.

19.6.2. Inspection requirements


a. Construction authority shall ensure inspections and tests have been completed before
submitting building for approval to commissioning authority.
b. Inspection and testing shall be performed in accordance with design requirements,
specifications, approved drawings, and to applicable national and state statutory
regulations and codes of country or state for which facility is subject.

19.6.3. Surface finish


a. Surface finish shall comply with design and specification requirements (e.g., tiled,
screeded, aluminium, plastic laminate, wood, or painted).
b. Surface coating shall be correct for quality and colour of finish and have no scratches,
blemishes, or defects.
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c. Recessed items, such as light switches, socket outlets, louvers, or where tiles are fitted,
shall be properly coated or otherwise properly finished.
d. Access hatches to concealed areas shall be correctly fixed, accessible, and labelled,
including warning notices as necessary.
e. Mouldings on skirting boards, ceiling, and wall joints shall be correctly fitted.
f. Ceiling tiles shall be in place and undamaged.
g. For suspended ceilings, suspension ties and supports shall be correctly installed.
h. Floor slope or camber to drains shall be correct, as applicable.

19.6.4. Windows and doors


a. Correct fire rated items shall be installed.
b. Finish around door and window frames shall be correct and complete.
c. Doors and opening windows shall function correctly and shall be correctly sealed if closed.
d. Hinges, locks, handles, and other similar hardware shall be installed and function correctly.
e. Glazing shall not be damaged in any way.

19.6.5. Fittings
Following applies to permanent fittings other than control panels:
a. Sanitary ware shall be undamaged.
b. Sealant, plugs, covers, taps, handles, and other similar hardware shall be correctly installed
and operational.
c. Mirrors shall be correctly installed and undamaged.
d. Wardrobe units, cupboards, and working surfaces shall be correctly aligned and doors shall
function correctly.
e. Locks, if installed, shall have keys and function correctly.
f. Edges around wardrobe units, cupboards, and working surfaces shall be correctly sealed
and undamaged.

19.6.6. Safety items


a. Fire extinguishers
1. Fire extinguisher brackets shall be installed in proper locations, with unrestricted
access at all times.
2. Fire extinguishers shall be of correct type, size, and correctly marked.
3. Operator may perform fire extinguisher installation.
b. Deluge, firewater, and sprinkler systems shall be inspected and tested in accordance with
applicable clauses of clause 11.1.5.
c. Hoses
1. Hose reels and associated valves shall be correctly installed and tagged and shall
operate freely.
2. Hoses shall be rolled out to ensure they are undamaged.
3. Hoses shall be correctly rerolled after inspection.
4. Doors, covers, and other items associated with hose reels shall operate freely.

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d. Emergency exit signs shall be of correct type and correctly located.


e. Escape routes shall be clearly marked and proper maps shall be installed.
f. Muster point cabinet locations shall be installed in proper locations.

19.6.7. Soft furnishings


a. Curtain rods, hooks, curtains, and blinds shall be installed and operate correctly and be of
correct colour.
b. Carpeting shall be of correct colour and correctly installed.
c. Chairs, tables, and other loose furniture shall be as specified.

19.6.8. Certification for buildings, fittings, and furnishings (architectural)


a. Approved Contractor building area acceptance certificate (GOC form BF1) shall record
results of inspections and surveys for modules, buildings, permanent offices, control
rooms, rest rooms, medical rooms, and associated facilities.
b. Acceptance of building area acceptance certificate by construction authority,
commissioning authority, or OA shall only confirm that area or collective areas are ready
for system handover (GOC form SH1).
c. Acceptance of building area acceptance certificate on its own shall not constitute system
handover or operator acceptance.
Electrical, control, and mechanical disciplines will be handed over on system basis.
Refer to appropriate section for relevant procedures and certificates.

20. Mechanical handling (lifting) equipment

Mechanical handling (lifting) equipment means any device used for lifting of
persons or things and includes:
Passenger lifts (elevators).
Cranes.
Winches.
Hoists.
Drilling derricks.
Lifeboat davits.
Runway beams.
Pad eyes.
Skips and cradles.
Hooks, lifting beams, wire rope slings, fibre slings, shackles, eyebolts, and flow
booms.
Lifting blocks, ropes, chains, and pulleys.

20.1. Inspection and testing

20.1.1. Overview

20.1.1.1. General
a. This clause provides recommended minimum requirements to indicate that mechanical
handling (lifting) equipment is installed and ready to be handed over to commissioning for
proof load testing.
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b. Installation, test, and inspection of lifting appliances shall comply with statutory and
mandatory requirements and appropriate and specific requirements for individual items as
described in BP standards and Vendor documents.
c. For site inspection and testing of totally enclosed motor propelled survival craft
(TEMPSC) davits (see clause 20.1.5), reference shall be made to appropriate regulations
and laws of country or state for whose jurisdiction offshore installation is subject.

20.1.1.2. Requirements
a. Requirements of this clause shall apply to mechanical handling (lifting) equipment being
erected or installed at site as permanent feature or associated with plant and equipment
being so erected or installed.
b. Mechanical handling (lifting) equipment shall undergo inspections and tests as described,
with resulting mandatory certificates required as part of system test dossier.
c. Certain classes of mechanical handling (lifting) equipment may require proof load testing
to be performed onsite, and these are highlighted in relevant procedures (e.g., main deck
cranes, lifeboat davits).
d. Any permanent mechanical handling equipment used by Contractor for construction shall
be recertified before handing over to BP.
e. Equipment not applicable
1. Requirements shall not apply to mechanical handling (lifting) equipment normally
owned and operated by Contractor that is used to facilitate construction process.
2. Contractor shall be responsible for compliance with statutory regulations applicable
to such equipment.
3. For reasons of safety, Contractor compliance with such regulations shall be verified
by inspector.
f. Third party involvement
1. Certain classes of mechanical handling (lifting) equipment shall require attendance of
third party to review or witness design or fabrication and testing.
2. Full range of lifting equipment requiring third party involvement shall be subject to
BP specification.

20.1.1.3. Mechanical procedures


a. Checks required to ensure that equipment is correctly installed and has been subjected to
proof load testing program shall be defined in mechanical handling procedures.
b. Installation completion checks shall generate approved Contractor mechanical handling
installation form (GOC form MH1).
c. Successful completion of mechanical handling installation certificate shall release
equipment for start of proof load testing program.
d. Proof load testing shall be recorded on approved Contractor mechanical handling
acceptance form (GOC form MH2).
e. With exception of passenger riding equipment, if load testing of fabrication yard installed
lifting appliance has been completed at Vendor site, testing is not normally repeated onsite.
f. Lifting appliances shall be load tested before:
1. Access is restricted (e.g., by installation of associated facility equipment [pumps,
skids]).
2. Painting or coating of appliance or structure to which appliance is attached.
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20.1.1.4. Statutory requirements


a. Visual examination and testing shall be performed by competent person.
b. In this clause, competent person shall be synonymous with inspector.
c. Inspector shall ensure that lifting equipment is inspected and tested in accordance with
either:
1. Applicable statutory requirements.
2. Plant inspection branch recommendations for items not covered by statutory
requirements.
d. Inspector shall ensure that Vendor inspection and testing recommendations are followed.
e. If there are no statutory requirements or if requirements are less stringent than U.K. or U.S.
regulations, more stringent shall apply.
f. Tests may be required to be witnessed by representative of insurance company or, in
certain countries, by representative of statutory authority.
Principal UK statutory regulations governing lifting equipment are:
Docks Regulations 1934 (SR&O 1934 No 279).
Factories Act 1961 (as amended by various repeals and modifications).
Offshore Installations (Operational Safety, Health, and Welfare) Regulations
1976 SI 1019.
Lifting Operations and Lifting Equipment Regulations 1998 (LOLER).
Principal U.S. statutory regulations governing lifting equipment are OSHA 29CFR
1910.179 Overhead and Gantry Cranes.

20.1.1.5. Applicable to all lifting appliances


a. During examination of lifting appliances, following shall be recorded on approved
Contractor mechanical handling acceptance form (GOC form MH2):
1. Parts not accessible for thorough examination.
2. Parts that require opening at next examination.
3. Defects and remedies
a) Particulars of defects and remedies.
b) Particulars of defects found in lifting appliance or lifting gear that affect safety.
c) Repairs (if any) required, either immediately or within stated specified time, to
enable lifting appliance to continue to be safely used.
4. Safe working load
a) SWL subject to repair, renewals, and alterations (if any) as specified in
clause 20.1.1.2.
b) For cranes with variable operating radii (including crane with derricking jib),
SWL shall be stated at various radii of jib, trolley, or crab (movable winch).
5. Verification that lifting equipment is free from damage or defects and correctly
installed.
6. Lifting appliances, such as cranes and lifts, shall undergo tests to verify proper
operations, with tests normally agreed upon between BP and Vendor.
7. Drivers and ancillary equipment shall be inspected and tested in accordance with
appropriate clause of this GP.
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8. Settings and functioning of safety devices that shall be checked and proved.
b. Third party examination of lifting appliances certificate that records load testing of
appliances and witnessed by competent person shall be acceptable alternate form.

20.1.1.6. Painting and marking of lifting appliances


a. Each item of lifting equipment shall have identification number that shall be clearly
marked thereon and shall be quoted on certificates and documents referring to item.
b. Identification numbers shall be agreed with operator and shall comply with overall
numbering sequence for site.
c. Trolley beams, lifting points (including associated supporting steelwork), and other
pertinent appliances shall be painted safety yellow.
d. Identification lettering
1. SWL information and equipment tag number shall be painted on appliances in black
characters at least 100 mm (4 in) high.
2. SWL information and equipment tag number shall be stamped into appliance at end
adjacent to operating position.
3. Lettering shall be legible from ground level and from operating position and routinely
applied on both sides.
4. Beams longer than 4,5 m (15 ft) shall have SWL information applied at each end.
e. For lifting points, requirements of c. and d. shall apply to associated supporting steelwork.
f. Vendor and site test certificates shall be compiled in HCP or appropriate dossier.
g. Dossier shall be available to operator before commissioning begins.
h. Following clauses cover various mechanical handling appliances:
1. 20.1.2: Cranes.
2. 20.1.3: Hoists, trolleys, and gantries.
3. 20.1.4: Trolley beams and pad eyes.
4. 20.1.5: Lifeboats and davits.

20.1.2. Cranes

20.1.2.1. General
a. This clause specifies checks to ensure that crane is correctly installed and has been
subjected to full proof load and function test.
b. Site inspection and testing of cranes shall comply with BP specifications, federal and state
requirements, or appropriate regulations and laws of country or state where installation is
located.
c. Cranes shall be erected and tested in accordance with Vendor approved procedures and
under supervision of Vendor representative.
d. Onsite welding or modification to crane shall be subject to authorisation by Vendor design
office, BP site engineers, and EA approval.
e. In addition to applicable clauses in clause 20.1.1.5, following shall be checked on cranes:
1. Mountings (turret, slewing ring) shall be checked against Vendor drawings for correct
installation.
2. Major fixing bolts shall be checked for correct grade and torque.
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3. Settings and function of safety devices shall be checked and tested or certified.
4. Wire rope
a) Wire rope systems shall be checked that they are reeved in accordance with
Vendor instructions.
b) Wire rope shall remain captive within sheave and drum and shall not foul crane
during operation.
5. Lubricants and coolants shall be checked for correct grade and quantity.
6. Vendor shall provide certification that includes following:
a) Crane as a whole, including statutory requirements.
b) Hooks.
c) Snatch blocks.
d) Wire ropes, hoist, and boom hoist.
e) Special tackle, lifting, and beams for crane maintenance.
f) Pressure vessels (air receiver for diesel air start).
g) Electrical and instrument items, including hazardous area certificates.
h) Structural steel and NDE reports.
i) Slewing rings and fastenings.
j) Loose equipment for handling crane (spreader beams, slings).
7. If load testing of crane has only been partially performed offsite, testing shall be
completed after crane is installed in permanent onsite location.
8. Cranes (pedestal and non pedestal) shall be proof load tested to statutory requirements
with certified test weights or calibrated load cell in presence of third party inspector
as designated by BP.
9. Fabrication certification and load test certification of supporting structure shall be
available in addition to crane load test.
10. Final examination
a) On completion of tests, thorough examination of crane shall be performed by
inspector to ensure no damage or permanent strain has occurred.
b) Some spot checking by NDE may be required at inspector discretion.
c) Hooks shall have NDE after load test.

20.1.2.2. Certification
a. Approved Contractor mechanical handling installation form (GOC form MH1) shall record
satisfactory completion of checks and requires endorsement to confirm that:
1. Required Vendor certification is correct and available onsite.
2. Requirements of clause 20.1.2 have been performed.
3. Crane has been installed in accordance with specified design.
b. Certificate shall be signed by construction authority before proof load testing.
c. Successful completion of mechanical handling installation certificate shall release crane
for start of proof load testing program.
d. Proof load testing certification shall be performed in accordance with clause 20.2.

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e. Crane may be commissioned in advance using temporary supplies and used as installation
aid during construction and commissioning of facility. Crane shall be recertified before
handing over to BP.

20.1.3. Hoists, trolleys, and gantries

20.1.3.1. General
a. This clause describes checks to ensure that hoists, trolleys, and gantries comply with
specification, are correctly installed, and have been subjected to full proof load test.
b. Site inspection and testing of this lifting equipment shall comply with BP specifications,
federal and state requirements, and appropriate regulations and laws of country or state
where installation is located.
c. Following shall be checked on hoists, trolleys, and gantries in addition to applicable
clauses in clause 20.1.1:
1. Lifting equipment shall be installed in accordance with Vendor approved procedures
and drawings.
2. Mounting beams, rails, and guides shall be inspected to ensure that installation
complies with specified geometrical tolerances.
3. Lifting devices themselves shall be checked against Vendor and design drawings for
correct assembly and installation.
4. Wire rope
a) Wire rope or chain systems shall be reeved in accordance with Vendor
instructions.
b) Wire rope or chain shall remain captive within sheave and drum and shall not
foul lifting elements during operation.
5. Safety catches on hooks shall function correctly.
6. Lifting equipment Vendor and third party inspection authority shall provide necessary
load test certification for equipment.
7. Trolleys and gantries shall be travelled over all working conditions to ensure there is
no interference with other equipment.
8. Partial disassembly
a) If equipment has been partially dismantled to aid installation, bolts removed
shall be replaced and torqued correctly.
b) If bolts were load bearing, equipment shall be tested as described in
clause 20.1.4.

20.1.3.2. Certification
a. Approved Contractor mechanical handling installation certificate (GOC form MH1) shall
be checked to record that lifting appliance has been installed correctly and that
requirements of clause 20.1.3 have been performed.
b. Successful completion of mechanical handling installation certificate shall release
installation for start of proof load test.
c. Certificate shall be signed by construction authority before proof load testing.
d. Proof load testing certification shall be performed in accordance with clause 20.2.

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20.1.4. Trolley beams and pad eyes

20.1.4.1. General
a. Procedure describes checks that shall ensure that trolley beams and pad eyes comply with
specification, are correctly installed, and have been subjected to full proof load test.
b. Site inspection and testing of lifting equipment shall comply with BP specifications,
federal and state requirements, and appropriate regulations and laws of country or state
where installation is located.
c. Following shall be checked on trolley beams and pad eyes in addition to applicable clauses
in 20.1.1:
1. Lifting equipment shall be installed in accordance with approved procedures and
drawings.
2. Trolley beams and pad eyes shall be checked against design drawings for correct
assembly and installation.
3. Bolts shall be checked to ensure correct grade and torque.
4. Site fabricated trolley beams, main attachment points, pad eyes, and other lifting
appliances shall be considered primary structure with respect to material traceability,
welding, and NDE.
5. For dedicated trolleys:
a) Dedicated trolley, if specified for trolley beam, shall preferably be tested with
trolley.
b) Hoists shall be trial erected on trolleys and pad eyes.
6. For non dedicated trolleys:
a) Trolley beams without dedicated trolleys shall be proof load tested using test
trolley.
b) This information shall be clearly stated on approved Contactor mechanical
handling acceptance form (GOC form MH2).
7. Lifting equipment shall be proof load tested to statutory requirements with certified
test weights or calibrated load cell in presence of third party inspector as assigned by
BP.
8. Safe working load
a) Trolley beams shall have SWL traversed along beam, and deflections shall be
checked at greatest span of beam.
b) Deflection shall not exceed 1/500th of span and 1/250th at SWL for cantilever
sections.
c) Overload of 1,25 times SWL shall be applied at point of maximum deflection,
deflection shall be measured and recorded, loads shall be removed, and
deflection shall return to zero.
9. Design Contractor shall specify pad eye design and test loads.
10. Items shall be stamped with identification tag data and SWL to show dedication to
particular mechanical handling installation.
11. Identification tag data, SWL, and limiting conditions shall be clearly painted on
trolley beam or adjacent to pad eye to be clearly visible to operator.
12. Completed proof load test.

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a) After completion of each proof load test, thorough examination of tested lifting
equipment shall be performed by inspection authority to ensure no damage or
permanent strain has occurred.
b) NDE shall be required.

20.1.4.2. Certification
a. Approved Contractor mechanical handling installation form (GOC form MH1) shall record
satisfactory completion of checks to be performed and requires endorsement to confirm
that:
1. Required certification is correct and available on site.
2. Requirements of clause 20.1.4 have been performed.
3. Lifting equipment has been installed in accordance with specified design
requirements.
b. Certificate shall be signed by construction authority before proof load testing.
c. Successful completion of mechanical handling installation form (GOC form MH1) shall
release installation for start of proof load testing.
d. Proof load testing certification shall be performed in accordance with clause 20.2.

20.1.5. Lifeboat davits and lifeboat

20.1.5.1. General
a. This procedure describes checks to ensure that lifeboat davits, lifeboats, and launch and
retrieval systems for offshore comply with specifications, are correctly installed, and have
been subjected to full proof load test.
b. Site inspection and testing of lifeboat and davits shall comply with appropriate regulations
and laws of country or state where offshore installation is located.
c. Lifeboat, davits, and launch and retrieval systems shall be installed and tested in
accordance with Vendor approved procedures under supervision of Vendor representative
and third party inspector.
d. Additional onsite welding or modification to davits shall be subject to authorisation of
Vendor design office and BP site engineer approval.
e. In addition to applicable clauses in clause 20.1.1, following shall be checked on lifeboat
installations:
1. Lifeboat, davits, and launch and retrieval systems shall be correct in all respects to
Vendor drawings.
2. Lifeboat, davits, and launch and retrieval systems shall be free from damage.
3. Lifeboat, davits, and launch and retrieval systems shall be installed as required by
Vendor design drawings and procedures.
4. Settings and function of safety devices shall be checked and proved.
5. Vendor shall provide certification to include following:
a) Lifeboat, davits, and launch and retrieval systems as a whole, including statutory
requirements.
b) Wire ropes, shackles, pulleys, and hoist.
c) Electrical and instrumentation cables and equipment.
d) Structural steel and NDE reports.
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e) Life support equipment.


6. Lifeboat and davits shall be:
a) Proof load tested as single unit after installation.
b) Witnessed by third party inspection as assigned by BP.
7. Further testing and drops to sea level shall be performed onsite in accordance with
subclause 6.
8. Proof load test completion
a) On completion of each part of proof load testing, thorough examination of
davits, lifeboats, and support structure shall be performed to ensure no damage
or permanent strain has occurred.
b) NDE shall be required.

20.1.5.2. Certification
a. Approved Contractor mechanical handling installation form (GOC form MH1) shall be
used to record satisfactory completion of checks to be performed and shall require
endorsement to confirm that:
1. Required Vendor certification is correct and available on site.
2. Requirements of clause 20.1.5 have been performed.
3. Davits, lifeboats (TEMPSC), and launch and retrieval systems have been installed in
accordance with specified design requirements.
4. Certification applies to onshore and offshore lifeboat installations.
b. Certificate shall be signed by construction authority before proof load testing.
c. Welding and NDE shall be recorded on appropriate forms and reports (refer to clause 10).
d. Successful completion of mechanical handling installation form (GOC form MH1) shall
release davits and lifeboat installation for proof load testing program (see clause 20.2).
e. If davits have been partially proof load tested prior to installation of lifeboat, second
mechanical handling installation form (GOC form MH1) shall be created for checking and
approving subsequent installation.

20.2. Commissioning

20.2.1. General
Before commissioning activities begin on system, following shall be completed and signed off
by construction and commissioning authorities on approved Contractor forms:
a. MC certificate (GOC form MC1).
b. Punch list (GOC form PL1).

20.2.2. Statutory load testing


a. Proof load test shall be performed with certified test weights in accordance with governing
regulations before item is accepted into service.
b. Proof load tests shall be performed at Vendor works.
c. Proof load tests may be acceptable instead of onsite tests.
d. Onsite tests (including testing of damaged or repaired items) shall be performed if required
by statutory regulations or if specified by BP.

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e. Lifting appliances, such as cranes and lifts, shall be tested to verify that they operate
satisfactorily, with testing requirements normally agreed upon between BP and Vendor.

20.2.3. Certification
a. Approved Contractor mechanical handling acceptance form (GOC form MH2) shall be
used to certify:
1. That proof load testing was successfully completed.
2. That installation is mechanically complete.
3. Existence of any other relevant certificates or restrictions.
b. Mechanical handling acceptance form shall be endorsed to confirm completion and
witnessing of proof load testing and, if installation was subjected to third party inspection,
shall have third party reports and test forms or certificates attached.
c. Form and certificate shall record defects, remedies, and recommendations from
examination of lifting appliances (on reverse side of GOC form MH2).
If GOC form JI1 is being used, completion of Part A and B of form is required
before system handover certificate can be signed and equipment can be safely
operated.

21. Painting, coatings, and insulation

21.1. Inspection and testing

21.1.1. General
Passive Fire Protection (PFP) was formerly known as fireproofing in BP
engineering codes and standards, a somewhat misleading term whose use has been
discontinued.
Although this GP excludes transmission pipelines, certain coating and wrapping
techniques are applicable to buried lines.
a. Inspector shall ensure compliance with particular specifications for surface preparation and
materials application operations and for materials themselves.
b. Key check points are:
1. Limiting ambient conditions (low temperature or high humidity) during painting and
blasting.
2. Time limit between surface preparation and painting operations and surface finish
compliance with post surface preparation immediately before painting.
3. Total DFT.
4. Protection of cold insulation against moisture penetration.
5. Proper fitting and sealing of cladding (jacketing) to protect thermal and acoustic
insulation from rain or deluge water.
6. Acoustic insulation placed over thermal insulation (if both are applied).

21.1.2. Painting and coating inspection


a. Prepaint and precoating inspection
1. Excluded surfaces and adjacent equipment shall be visually inspected for protection
from damage during coating operations.

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2. Sharp edged surface imperfections detrimental to coating performance (e.g., weld


spatter, protrusions, delaminations) shall be visually inspected.
3. Visual inspection for cleanliness shall be performed in accordance with SSPC
Vis 1-89 and SSPC Vis 3, or equivalent as appropriate.
4. Anchor pattern profile shall be measured each 9,3 m2 (100 ft2) using replica tape in
accordance with NACE RP0287.
b. During and after coating application, in process inspection shall be as follows:
1. Visual inspection of coated surfaces for runs, sags, blisters, and other imperfections
detrimental to coating performance. Each coat shall be inspected.
2. Dry film thickness
a) Coating DFT measurement shall comply with SSPC PA 2 or equivalent.
b) DFT measurement shall be performed with BP approved DFT gage calibrated
against NBS calibration standards in accordance with ASTM D1186 or
equivalent.
c) Measurement shall be witnessed by Vendor technical representative or BP
representative.
d) Failure to meet specified thickness ranges shall cause work to be rejected.
3. Air used in blasting and coating application shall be checked for condensed water and
oil at start of each shift and at least every 4 hours thereafter during shift.
4. For surfaces undergoing surface preparation or coating application, surface
temperature, relative humidity, and dew point shall be determined at start of each shift
and at least every 3 hours thereafter during shift or at other specified intervals.
5. Coatings and linings shall be inspected for holidays in accordance with project
specifications.
6. Barcol hardness readings shall be performed on liners in vessels and tanks.
c. Coating applicator shall maintain and provide inspection documentation as follows:
1. Written inspection procedure outlining inspection and testing and inspection
personnel responsibilities.
2. Written weekly progress reports containing daily information, including:
a) Area prepared and coated.
b) Materials used.
c) Specific problems encountered.
d) General status.
3. Final written report containing detailed summary information, including:
a) Total area coated.
b) Abrasives used.
c) Coating and thinner product designations with batch numbers.
d) Mixing and thinning procedures.
e) Inspection results.
f) Specific problems encountered with causes and solutions.
g) Time breakdown.

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h) Comments and recommendations.

21.1.3. Insulation inspection


a. Insulation shall be installed as specified by BP (e.g., type, thickness, weatherproofing).
b. Valve access and operability shall not be obstructed by insulation.
c. Insulation shall be properly anchored and secured to item insulated.
d. Vapour barriers shall be in place for cold piping.
e. Cladding and jacketing shall comply with specification as stated by BP.
f. Corrosion monitoring pockets shall be identified and correctly installed.

21.1.4. Passive fire protection (PFP) inspection


a. Inspector shall ensure compliance with project specifications and Vendor recommended
application of PFP material.
b. Key check points are:
1. Verifying correct material of application and area PFP against equipment and
structural drawings showing details of PFP extent.
2. Verifying application thickness required for specified fire rating to be obtained in
accordance with project specifications.
c. PFP completion:
1. Upon completion of PFP, Contractor and subcontractor (if used) shall issue certificate
of acceptance verifying that PFP complies with Vendor requirements and BP
specifications.
2. After independent verification of these conditions, certificate of acceptance shall be
signed by Contractor quality assurance or quality control representative, Vendor
technical representatives, and BP representatives.
3. Applicator shall additionally furnish properly completed Vendor official certification
form to provide record of installation for code or insurance requirements, as
applicable.

21.1.5. Certification
a. Approved Contractor final paint acceptance certificate (GOC form AS1) shall be used to
record acceptance on completion of painting.
b. Form shall be completed by construction and commissioning authorities.
c. This certificate shall ensure that:
1. Painting complies with drawings and specifications.
2. Applicable requirements of clauses 21.1 through 21.1.4 have been performed
satisfactorily.
d. Approved Contractor final insulation and coating acceptance certificate (GOC form AS2,
part 1) shall cover piping, architectural and structural acceptance (paint, linings, and PFP),
and be used to record acceptance for insulation, PFP, and related activities.
e. Certifying authority (i.e., fire marshal or other authorised representative of country or state
where installation is located) may be required to endorse document to certify PFP.
f. Document shall be completed by construction and commissioning authorities and shall
ensure that:
1. Painting, coating, or PFP complies with drawings and specifications.
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2. Applicable requirements of clauses 21.1 through 21.1.4 have been performed


satisfactorily.

22. Electrical (NEC)

Due to differences in the way electrical equipment and circuits are tested around the
world, electrical topics in this GP are divided into two clauses.
Clause 22 covers requirements of National Electric Code (NEC) that is used widely
in the Western hemisphere. GOC forms referenced in clause 22 have abbreviation
WH to designate source is GOC for the Western hemisphere.
Clause 23 covers requirements of International Electrotechnical Commission (IEC)
and European Committee for Electrotechnical Standardisation (CENELEC) that is
used widely in the Eastern hemisphere. GOC forms referenced in clause 23 have
abbreviation EH to designate source is GOC for the Eastern hemisphere.
Clauses 22 and 23 both cover site inspection of electrical equipment and inspection
and testing of installed equipment and circuits before commissioning and after
initial energisation.
Equipment and circuits normally include:
Power generation and distribution systems at all voltages.
Cabling systems for electrical power and control systems. Cabling systems
associated with instrumentation and telecommunications systems may be
included.
DC equipment and power supplies, including batteries.
AC and DC electrical motors and associated switchgear and control equipment.
Lighting and small power systems.
Navigation, safety, and warning systems (such as sirens and flashing beacons).
Earthing (grounding) and bonding systems.
Procedures in clause 22 contain some preinstallation and post installation
procedures and functional testing procedures. Basis for identifying which
procedures fall in I&T (22.1) or commissioning (22.1.19) was selected from BP
GOC functional certification flowchart categorising fabrication and construction
that includes I&T in powered down (non energised) state and commissioning that
includes functionality checking activities in powered (energised) state. Review of
these procedures is advised before implementation due to mixture of I&T and
commissioning activities in each procedure.

22.1. Inspection and testing

22.1.1. General
a. Procedures in this clause detail onsite and offsite I&T for electrical discipline and include
references to GOC forms that are highly recommended for recording I&T results.
b. Forms shall provide written evidence that electrical equipment and circuits comply with
design parameters and function correctly.
c. Procedures in this clause cover:
1. Inspection of equipment before installation.
2. I&T of installed equipment and circuits before energisation (construction phase).
3. I&T of installed equipment and circuits after energisation (commissioning phase).

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d. Complete I&T procedures


1. I&T in this clause is comprehensive, but may not necessarily cover all electrical
equipment and circuits included in design.
2. Construction and commissioning group shall:
a) Confirm validity of electrical inspections and tests.
b) Ensure that procedures additional to those in this GP shall be developed to
provide more complete coverage, if necessary.
c) Confirm that electrical circuits are fit for energisation and service.
e. Equipment list and cable schedule
1. Engineering and procurement group shall ensure that comprehensive component or
equipment list and cable schedule is available before inspection and testing.
2. Required test certificates shall be checked against list in 1. to provide concise
crossreference for completion of system testing.
3. Lists in 1. shall form index of certification database for electrical.
f. Vendor requirements
1. Vendor may be required to perform final inspection and functional testing onsite after
installation.
2. I&T in 1. shall be recorded on approved Contractor test forms (or GOC test
certificates) unless specific test certificates are prepared by Vendor and agreed upon
by WA before use.
g. Requirements described herein that apply to equipment specified for installation in
compliance with NFPA 70/NEC Class I, Division 1, hazardous locations shall also apply to
that same equipment if installed in Class I, Division 2, or nonhazardous areas, subject to
BP approval.

22.1.2. Installation
a. Electrical equipment and electrical content of mechanical equipment packages shall be
inspected upon onsite receipt.
b. Remedial work performed onsite by Vendor to correct transit damage or faulty
workmanship not previously detected shall be supervised by construction authority.
c. See clause 7 for requirements of inspection of equipment upon onsite receipt.
d. Final I&T of electrical equipment and systems performed onsite by Vendor representatives
shall be witnessed and formally accepted by construction or commissioning group
electrical engineer.
e. Before performing inspection or tests in d., WA shall be informed, and WA shall identify
inspection or tests that are required to be witnessed.

22.1.3. Preacceptance

22.1.3.1. Preparation
a. Inspection notification
1. Before energising, if construction authority considers installation of electrical circuit
or part thereof is complete and is of such standard that preacceptance inspection and
testing can begin, WA shall be advised accordingly.
2. Unless WA gives specific waiver, representative of WA shall witness inspection and
tests to be recorded in HCP.
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3. Construction authority shall provide adequate notice of intention to begin activities


such that WA has time to allocate necessary personnel.
4. WA shall monitor construction activities such that I&T can be performed as work
proceeds.
b. Inspection completion
1. Disconnecting cables for testing after installation has been completed should be
avoided.
2. If possible, final I&T shall be performed immediately before acceptance for
energisation. If not possible, WA may call for reinspection and retesting.
3. Following satisfactory completion of I&T of system or circuit, construction authority
or WA shall complete appropriate test certificates that shall be witnessed by WA and
submitted before formal notification that work on circuit is complete.
4. No further work shall be performed on completed circuit subsequent to certificate
submittal unless WA or commissioning authority agrees in writing to full details of
such work.
5. Further work description shall contain full details of branch circuits not covered and
shall include means by which those circuits shall be isolated during added work.
c. Test equipment
1. Equipment for testing, such as meggers, DC high potential test sets, and current
injection test sets, shall be calibrated every 6 months and comply with industry
standards.
2. Certificates of calibration shall be included with system handover package and
matched with test equipment serial numbers.
d. Test conditions
1. Module or work enclosure internal ambient temperature during testing shall be
maintained from 4C to 27C (40F to 80F).
2. Ambient temperature and relative humidity shall be recorded at beginning of each
test.

22.1.3.2. Witnessing authority performing test or verify test


Commissioning authority and WA tests are separated into two categories, in which WA shall
perform test and verify test, as follows:
a. WA shall perform test:
1. With exception of clauses 22.1.13 for grounding and bonding, 22.1.14 for equipment
in hazardous locations and 22.1.16 for instrument transformer verification, certain
tests shall be performed after energisation.
2. Procedures requiring completion by commissioning authority and WA are indicated
by WA shall perform test at end of each test description clause.
3. Commissioning authority and WA shall be responsible for completing energised tests
in 1. and 2., recording results, and signing off and completing certificates.
If GOC certificates are used, items requiring completion by commissioning
authority and WA are marked with double asterisk (**), indicating that WA shall
perform test.
4. GOC WH certificates affected by this delineation (energised tests) where WA shall
perform test are:

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Clause Certificate/Form Test


22.1.5 EE2 sheet 01& 02 MCC inspection for bus duct phase rotation (see form 22.7)
22.1.6 EE3 sheet 01, 02 & 03 Circuit breaker tests for trip circuit operation (see form 22.9)
22.1.7 EE4 sheet 01 Contactor starter for trip circuit operation and breaker status
remote indication
22.1.10 Form22.12 Illumination and emergency lighting tests
22.1.12 EE8 sheet 02 Heat trace performance test
22.2.6 EE13 sheet 01 Phase rotation and run testing of motors
22.2.7 EE18 sheets 01 and 02 AC generators
22.2.8 EE4 sheet 03 Load testing variable speed drives
22.2.9 EE14 sheets 01 and 02 Battery test
22.2.10 EE15 sheet 01 UPS performance testing

b. WA shall verify test.


1. Electrical procedures that require witnessing points during construction shall be
indicated by WA shall verify at end of test description clause.
2. Construction scope I&T shall be completed if procedural clause lacks statement WA
shall perform test.
Construction work scope I&T on GOC certificates is completed if asterisks do not
appear on form.

22.1.4. Power, control, and instrument cables

22.1.4.1. General
Following I&T procedures in clauses 22.1.4.2 through 22.1.4.8 shall apply to all cable sizes and
types.

22.1.4.2. Inspection
a. Before installation
1. Cable protection
a) Cables and accessories shall be protected from weather.
b) Ventilation shall be provided to prevent condensation.
c) Both ends of cables shall be sealed to protect cables from dirt and moisture
during storage.
d) Protective cribbing shall remain on cable reels until construction is ready to
receive cable.
2. Cable trays
a) Conduit and cable tray shall be inspected before cables are installed (see
forms 22.1 and 22.4).
b) Seal sizes and locations shall be verified before conductors are installed in
conduit.
3. Cable type
a) Cable shall be proper type, size, and rating for designated application.
b) Required manufacturing data and standards labelling in accordance with NEC
shall be clearly visible on cable.

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4. Exposed sections of cables shall be inspected for exterior mechanical damage.


5. Insulation resistance
a) Insulation resistance tests shall be performed while cable is on reel.
b) Test results shall be recorded on approved Contractor cable test certificate (GOC
form EE1, sheets 01 and 02).
b. After installation
1. Labelling
a) Cable size, type, routing, and numbering (labelling) shall comply with cable
schedule and relevant electrical drawings.
b) Colour code and wire numbers shall match connection diagrams and phase
sequence.
c) Special requirements shall be noted, such as chemical environment, service
voltage, and area classification.
Caution: Extension wire type for thermocouples can easily be incorrectly installed.
2. Terminations
a) Cable terminations and fittings shall comply with area classification and
specifications.
b) Cable termination fittings shall have proper tightness and show good
workmanship.
c) Termination fittings shall be correct for size and type of cable installed and
landed connection.
d) Wiring shall be properly dressed to allow easy access to terminations.
3. If three phase loads are served by either single conductor or parallel conductors for
each phase, phase conductors shall be grouped (A, B, C, N) in accordance with NEC
to prevent induction heating of conduit or enclosure.
4. Compression connectors
a) Conductors, if terminated with compression connectors, shall have correct size
and type of connector.
b) Crimp tool and dies shall be listed and labelled for particular connector.
c) Crimp tool shall require full compression stroke before release.
d) Compression applied connectors shall have correct cable match and indentation.
5. Bolt and torque connections
a) Cable connections shall be tight and torque values shall be verified with
calibrated torque wrench in accordance with Vendor published data.
b) In absence of Vendor data, Table 4 shall be used.
6. Grounding
a) Grounding connections for control and power cables shall be inspected to ensure
correct installation.
b) Vendor instructions shall be consulted for proper ground connections for cable
type.

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Table 4 - U.S. standard fastener torque values for electrical connections

Part 1
Heat treated steel - Cadmium or zinc plated
Grade SAE 1&2 SAE 5 SAE 7 SAE 8

Head marking

Minimum tensile
2 64k 105k 133k 150k
strength (lb/in )

Bolt diameter (in) Torque (ft-lb)


1/4 4 6 8 8
5/16 7 11 15 18
3/8 12 20 27 30
7/16 19 32 44 48
1/2 30 48 68 74
9/16 42 70 96 105
5/8 59 96 135 145
3/4 96 160 225 235
7/8 150 240 350 380
1,0 225 370 530 570
Part 2
Silicon bronze fasteners
Torque (ft-lb)
Bolt diameter (in) Nonlubricated Lubricated
5/16 15 10
3/8 20 14
1/2 40 25
5/8 55 40
3/4 70 60
Note: Part 2 is based on bronze alloy bolts with minimum tensile strength of 70,000 lb/in2.
Part 3
Aluminium alloy fasteners
Torque (ft-lb)
Bolt diameter (in) Lubricated
5/16 8
3/8 11,2
1/2 20,0
5/8 32,0
3/4 48,0
Note: Part 3 is based on aluminium alloy bolts with minimum tensile strength of 55,000 lb/in2.

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Part 4
Stainless steel fasteners (2)
Torque (ft-lb)
Bolt diameter (in) Uncoated
5/16 14
3/8 25
1/2 45
5/8 60
3/4 90
Notes:
1. Caution: If checking tightness of electrical connections, do not attempt to loosen or break loose
connection that is already tight. Set torque wrench at appropriate torque setting and tighten only
until wrench releases.
2. Part 4 is for following hardware types: Bolts, cap screws, nuts, flat washers, locknuts (18-8 alloy),
and Belleville washers (302 alloy).
3. Consult Vendor for equipment with metric fasteners.
4. Table source: NETA Maintenance testing specifications for electrical power distribution equipment
and systems.

7. Medium voltage cables


a) MV cables (including shield grounding) shall be terminated in accordance with
Vendor instructions.
b) Required support or clamping shall have proper strain relief.
c) Terminations shall be adequately corona suppressed by guard ring, field
reduction sphere, or other suitable method, as necessary.
d) Depending on voltage and type of cable, stress cones may be required for corona
suppression.
8. Mineral insulated (MI) cable
a) Termination fittings shall comply with Vendor instructions.
b) Insulating sleeves shall be undamaged.
c) Pigtails shall be stranded wire.
d) Pigtail length and root length shall comply with NEC.
e) Individual MI cable sets shall have megger tests for insulation resistance.
f) MI cable shall have vibration suppression loops.
9. Conduit and cable trays
a) Conduit, cable trays, and cabling systems shall comply with NEC and IFC
drawings.
b) Inspection data for applicable conduit, cable, or cable tray shall be recorded on
forms 22.1 through 22.4.
10. Cable blocking kit
a) Cable blocking kit (as required for hazardous locations) shall be properly
installed.
b) Inspection data shall be recorded on form 22.5 and attached to approved
Contractor general test certificate (GOC form WH EE16, sheet 1).

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11. Cable bends


a) Cable installation bends shall comply with Vendor specifications, Insulated
Cable Engineers Association (ICEA) standards, and NEC minimum allowable
bending radius.
b) Cables routed through pull boxes and panels shall be closely inspected.
12. Installation shall comply with following special requirements for conduit seals and
other details, as applicable:
a) Hazardous locations (see clause 22.1.14).
b) Junction box standards (see clause 22.1.17).
13. Inspection checkout forms 22.1 through 22.5 as follows shall be attached to approved
general test certificate (GOC form WH EE16, sheet 01) to assist in organisation of
data and ensure acceptance.
Form Description
22.1 Conduit installation inspection
22.2 Conduct or cable seal inspection
22.3 Cable inspection
22.4 Cable tray installation inspection
22.5 Cable blocking kit installation inspection

Note: Conduit, cable, and cable tray inspections shall be


completed before insulation tests (megger or high voltage
DC). Insulation tests shall be performed with cables installed
but with end terminals still open.

22.1.4.3. Cable testing


a. Before cables are tested, cable supports, strain relief or clamping blocks, and pull box or
termination cabinets shall be installed.
b. Final cable tests shall be performed with cable runs essentially in place and before final
terminations are made up.
c. Megger tests
1. Before final megger tests, open end of cable shall be isolated from conducting
material and three phases (plus neutral if used) shall be prepared and made accessible
at testing end.
2. Megger test shall be performed on one phase conductor to ground with other
conductors grounded and shields (if used) grounded.
3. Test conductor shall be rotated to test three phases individually in same manner.
d. Multiconductor cable tests
1. For multiconductor cables, insulation resistance tests shall be performed from
conductor to other conductors, grounded one at a time with shields grounded.
2. Additional test shall be performed to confirm isolation between shield and armour if
both are in same cable.
3. Lowest test value obtained on each test shall be recorded.

22.1.4.4. Insulation resistance test for installed cable


a. Cable insulation resistance shall be measured and recorded on proper approved Contractor
cable test certificates (GOC WH form EE1, sheets 01 and 02).
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b. Table 5 contains test voltages and minimum acceptable insulation resistance values.
c. Test duration shall be 1 minute to verify minimum cable insulation before further HV tests.
WA shall verify

Table 5 - Insulation resistance test

Cable AC voltage (see Test voltage between Minimum insulation resistance


IEEE 576-2000 rating) conductors and ground (megohms)
(operating range) (VDC)
300 V 500 50
600 V 1 000 50
5 kV 2 500 5
15 kV 5 000 15
Notes:
1. Test duration is 1 minute.
2. Table source: NETA Acceptance Specifications for Electrical Power Distribution Equipment and
Systems.

22.1.4.5. High voltage acceptance test (DC) for MV and HV cable


a. Before proceeding with HV test:
1. Insulation resistance tests in clause 22.1.4.4 shall be performed.
2. Residual current from tests in clause 22.1.4.4 shall be grounded and discharged.
b. Test voltage
1. For new cable systems, test voltage shall comply with Table 6.
2. For subsequent retesting after test failure and repair or for cable systems consisting of
new and previously in service cable, test voltage shall be 80% of acceptance test
values in Table 6.

Table 6 - High voltage DC test values

Cable System Acceptance Maintenance test 5 kV step Test voltage


voltage basic test voltage voltage (conductor duration duration at
operating impulse (conductor to ground) (minutes) maximum
range insulation to ground) (VDC) (minutes)
(Volts) level (BIL) (VDC)
(Volts)
5 kV 75 kV 25 kV 20 kV 1 15
15 kV 110 kV 55 kV 40 kV 1 15
35 kV 200 kV 100 kV 75 kV 1 15

c. Test procedure (see IEEE 576-2000)


1. HVDC shall be applied between each conductor and ground, with other conductors
and shields grounded.
2. For each step and for maximum volts, following shall be recorded on approved
Contractor cable test certificates (GOC form WH EE1, sheets 03 and 04): test voltage,
duration and value of test voltage, leakage current and computed resistance (from
measured volts/amps [V/I].
3. Conductor test potential shall be reduced to zero and voltage measured at discrete
intervals in accordance with IEEE 400-1991.
4. Test shall be repeated for each conductor of each cable.

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5. Completed cable run, including end service terminations, shall be tested at 100% of
cable rated voltage for 15 minutes. Note that load circuit shall be open for this test.
6. Test in 5. shall confirm proper resistance of conductor to conductor and conductor to
shield. Should readings be unsatisfactory, each conductor to its shield and conductor
to conductor shall be selectively tested to isolate fault.
d. If Doble power factor test shall be performed, test should be performed after high potential
testing is complete and cables are fully discharged (see NFPA 70B, clause 209.32).
e. Cable systems with splices
1. For cable systems with splices, each cable segment between splices shall be tested as
individual cable before making up splices.
2. To ensure splice integrity, each splice shall then be individually tested at rated
operating voltage for 1 minute or until leakage current is stabilised.
f. After testing, each cable shall be discharged and conductors shall be grounded and tagged
until cable is ready to be terminated on both ends.
WA shall verify

22.1.4.6. Conductor continuity test


a. Precision continuity test shall be performed on conductors, including MV shield, with
volt/ohmmeter or potentiometer to ensure conductor integrity.
b. Shield resistance shall be measured by looping shield on two adjacent conductor shields
together at one end and measuring loop resistance with accurate volt/ohmmeter.
c. Test shall be repeated for each conductor pair combination.
d. Results shall be recorded.
WA shall verify

22.1.4.7. Cable blocking kits


Cable blocking kits, if required to seal cables leaving hazardous locations, shall be inspected for
correct installation.
WA shall verify

22.1.4.8. Conduit seals


a. If conduit seals are required in hazardous locations, correct materials and methods for
installing, sealing, and packing shall be verified before pouring of any seals.
b. Poured seals shall be inspected.
c. If inspection is satisfactory, seals shall be marked by painting seal plugs red with plugs
tight.
WA shall verify

22.1.4.9. Certification
a. Following approved Contractor certificate forms, as applicable, shall be used to record
completed inspection and testing results and shall be endorsed by WA to confirm
requirements in clauses 22.1.4 have been performed satisfactorily.
1. LV shielded instrument cable test certificate (GOC form WH EE1 sheet 01).
2. Cable and wire insulation resistivity certificate (GOC form WH EE1 sheet 02).
3. Cable DC high potential step voltage certificate (GOC form WH EE1 sheet 03).

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4. Insulation resistance and DC high potential test graph (GOC form WH EE1 sheet 04).
5. General test certificate (GOC form WH EE16 sheet 01).
b. Inspection checkout forms 22.1 through 22.5 shall be attached to approved general test
certificate (GOC form WH EE16, sheet 01). See clause 22.1.4.2.b.13.
c. Additional procedures, if applicable, from clauses 22.1.14 (equipment in hazardous
locations) and 22.1.17 (junction box inspection) shall be confirmed that they have been
satisfactorily performed by WA.

Form 22.1 - Conduit installation inspection checkout

CONDUIT INSTALLATION SLD No SHT of


INSPECTION CHECKOUT (Procedure 22.1.4)
DATE: JOB NO: LOCATION: MODULE:
CONDUIT NO: SIZE: FROM: TO:
Initials/Date
1. Conduit fittings and junction boxes correct type for area of classification. Covers on 1
condulets, junction boxes, and raceways secured with fastening devices and fitted
with gaskets as required.
2. Aluminium or galvanised steel conduit installed as specified on drawings. 2
3. Supports installed and spacing per drawings, specs, and NEC. Expansion fittings 3
installed as required.
4. Supports adjacent to terminal boxes or devices per NEC. 4
5. Conduit is correct size per drawings and NEC fill requirements. 5
6. Conduit field cut correctly threaded per NEC. 6
7. Conduit installed wrench tight with minimum 5 threads engaged. 7
8. Conduit installed plumb and level, at right angles to structure. 8
9. Conduits clean, stub ups protected, open ends plugged and free of obstructions. 9
10. Conduit bending radius is correct per specs, IECA, and NEC. Bends free of 10
deformities with full diameter throughout.
11. Installation is neat and conduct runs evenly spaced. 11
12. Spacing between instrument and power conduits is per project specs. 12
13. Spacing from hot piping or equipment is in accordance with project specs. 13
14. Adequate clearance maintained from walls, ladders, railings, and ceilings. 14
15. Conduit permanently and effectively grounded per NEC and clause 22.1.13. 15
16. Threaded bushings installed on conduits entering boxes, fittings per NEC. 16
17. Seals, drains, and breathers installed per drawings, specs, and NEC. 17
18. Union installed between seal and devices or boxes. 18
19. No fittings installed between seals and crossover area classification boundaries. 19
20. Junction boxes level and supported per drawings with proper hubs, locknuts, and 20
bushings installed.
21. Junction boxes properly labelled and grounded. 21
22. Number of pulling points adequate; number of bends does not exceed NEC. 22
Flexible conduit installed with correct bending radius.
REMARKS

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Form 22.2 - Conduit or cable seal installation inspection checkout

CONDUIT OR CABLE SEAL INSTALLATION SLD No SHT of


INSPECTION CHECKOUT (Procedure 22.1.4)
DATE: JOB NO: LOCATION: MODULE:
Conduit or cable number and location Type (eys, stx) Size

Verify Initials/Date
1. Temperature suitable for pour __________ (C or F) 1
2. Temperature maintained for seal cure per Vendor requirements. 2
3. Seals properly sized per specifications and codes. 3
4. Seals properly located per code. 4
5. Packing material type and installation per Vendor requirement. 5
6. Conductors properly separated. 6
7. Proper compound type and mixed per Vendor requirements. 7
8. Seals checked for leak through after pour. 8
9. Seal plugs painted red. 9
10. Seal or STX initialled and dated by BP QA. 10
REMARKS
a. Verify seal sizes and location prior to installation of any conductors into conduit system.
b. Seals shall not be poured until conductors have been tested.

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Form 22.3 - Cable (installed without conduit) inspection checkout

CABLE (INSTALLED WITHOUT CONDUIT) SLD No SHT of


INSPECTION CHECKOUT (Procedure 22.1.4)
DATE: JOB NO: LOCATION: MODULE:
CABLE NO: SIZE: FROM: TO:
Verify Initials/Date
1. Cable, fittings, and junction boxes labelled or listed for area classification. 1
2. Supports installed per drawings, specs, and NEC. 2
3. Supports installed at terminal boxes and devices per NEC. 3
4. Cable sized per drawings. 4
5. Cable terminators packed and sealed as required. 5
6. Terminators are wrench tight with minimum 5 threads engaged. 6
7. Cables are installed plumb and neatly arranged. 7
8. Cable bending radius is correct per specs and NEC. 8
9. Cable installation is neat and evenly spaced. 9
10. Spacing between instrument and power cables is per project specs. 10
11. Spacing from hot piping or equipment in accordance with project specs. 11
12. Adequate clearance maintained from walls, ladders, railings, ceilings, and sharp 12
edges.
13. Cable is permanently and effectively grounded and bonded per NEC. 13
14. Hubs and bushings installed for cable terminations as required. 14
15. No fittings installed between seals and area classification boundaries. 15
16. Junction boxes properly installed with proper hubs, bushings installed, labelled and 16
grounded.
REMARKS

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Form 22.4 - Cable tray installation inspection checkout

CABLE TRAY INSTALLATION SLD No SHT of


INSPECTION CHECKOUT (Procedure 22.1.4)
DATE: JOB NO: LOCATION: MODULE:
TRAY NO: SIZE: FROM: TO:
Verify Initials/Date
1. All braces and supports installed per drawing, specs, NEC, and VE-1. 1
2. Aluminium or galvanised conduit attachments installed as specified on drawings. 2
3. Tray size and fill in accordance with specs, NEC, and VE-1. 3
4. Tray hold downs and guides properly installed/located per design, NEMA, and 4
NEC requirements.
5. No sharp edges left and round carriage bolts are installed with head to inside of 5
tray.
6. Field bends and transitions provide continuous bonding for ground path and 6
proper support for cables.
7. Bonding jumpers installed as required at section junction points. 7
8. All nonconductive coatings removed at ground and bond connections as required. 8
9. Cable tray grounded and bonded as required. 9
10. Proper clearances provided as required for installing cable runs in tray. 10
11. Expansion joints located as required properly installed and bonded. 11
12. Damaged coatings repaired as required. 12
13. Spacing between power and instrument trays maintained per specs. 13
14. Proper spacing from heat sources per specs. 14
15. All dividers, covers, and fire stops installed as required by specs and NEC. 15
REMARKS

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Form 22.5 - Cable blocking kit installation inspection checkout

CABLE BLOCKING KIT INSTALLATION SLD No SHT of


INSPECTION CHECKOUT (Procedure 22.1.4)
DATE: JOB NO: LOCATION: MODULE:

TRAY NO: SIZE: FROM: TO:


Verify Initials/Date
1. Cable jacket and shields properly prepared for blocking. 1
2. Aluminium or galvanised conduit fittings installed as specified on drawings. 2
3. Drain wires insulated with clear heatshrink tubes. 3
4. Proper gap (1/2 in) between drain heatshrink tubing and end of shield foil. 4
5. Proper number of sealant sleeves used per Vendor requirements. 5
6. Individual drain wires grouped in common with their conductors. 6
7. No visible cracks or defects in sleeves or fittings. 7
8. No share bends at block mounting. 8
9. Hot melt sealant evenly distributed. 9
10. Hot melt sealant visible at both ends. 10
11. No individual conductors or shield wire showing. 11
12. Overall heat shrink is properly positioned. 12
13. Overall heat shrink length is per Vendor specification. 13
14. Cable types compatible with blocking. 14
REMARKS

22.1.5. Switchgear, motor control centres, and metal enclosed bus duct

22.1.5.1. General
Inspection and test procedures in clauses 22.1.5.2 and 22.1.5.3 shall be applicable to following:
a. Switchgear.
b. MCCs.
c. Metal enclosed bus ducts.

22.1.5.2. Inspection
a. Before installation
1. Specifications
a) Equipment documents and certificates that certify area classification and
specification requirements shall be met.

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b) Equipment shall be compared with drawing schedules and items verified with
bill of material, with particular attention paid to ratings and circuit designations.
c) Required connection and detail hardware shall be included in shipment.
2. Cleanliness
a) Temporary weatherproofing and silica gel drying materials shall be removed
from switchgear and enclosures.
b) Inside of switchgear and enclosures shall be clean.
c) Inside of switchgear or enclosures shall be free of moisture, with particular
attention paid to insulators and bus bracing.
3. Equipment shall comply with environmental specifications, including weather, dust,
and vermin proofing.
4. Equipment shall not be damaged.
5. Required maintenance equipment (fuse pullers, racking mechanism), connection and
detail hardware, and other necessary hardware shall be included in shipment and
properly listed on shipping documents.
b. After installation
1. Assembly details
a) Switchgear and MCC assemblies shall be inspected for alignment, plumb, and
level.
b) Anchor and foundation bolts shall be checked for tightness.
c) Assembly hardware shall be installed and torqued to specified values in
accordance with Vendor drawings and BP specifications.
d) Equipment shall be new and in good clean condition.
e) Filters shall be in place and vents shall be clear, as applicable.
f) Bolt torque
i. Bolt torque at bus connection points shall be verified with calibrated torque
wrench in accordance with Vendor data.
ii. In absence of Vendor data, bolt torque values in Table 4 shall be used.
WA shall verify
2. Electrical
a) Panel doors and termination plates shall be bonded to enclosure structures.
b) Equipment grounding bus and grounding electrode conductors shall have proper
electrical and mechanical continuity in accordance with NEC.
c) Insulation and supports
i. Bus, insulation, and supports shall be inspected for tightness.
ii. Insulators shall not have physical damage or contaminated surfaces.
iv. Joint insulation shall be correctly installed and in specified location.
v. Housing and bus connections shall be in proper alignment.
vi. Bolts at bus connection points shall be checked calibrated torque wrench in
accordance with Vendor data. In absence of Vendor data, use bolt torque values
in Table 4 shall be used.

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WA shall verify
d) Proper operation and sequence of interlock system (Kirk Key or electrical)
between main and tie circuit breakers on installed switchgear and transfer
schemes in MCCs shall be verified.
e) Correct barrier and shutter installation and operation shall be verified, as
applicable.
3. Applicable requirements of clause 22.1.14 shall be met.
c. Inspection checkout
1. Inspection checkout forms 22.6 through 22.8 shall be used to assist in completing
requirements of appropriate acceptance certificates.
2. Completed forms shall be attached to associated acceptance certificate.
Equipment Form Description Acceptance certificate
Electrical switchgear 22.6 Electrical switchgear Switchgear bus insulation and
inspection checkout phasing test certificate
(GOC form WH EE2, sheet 01)
MCC 22.7 MCC inspection MCC bus insulation and phasing test
checkout certificate
(GOC form WH EE2, sheet 02)
Bus duct 22.8 Bus duct inspection General test certificate
checkout (GOC form WH EE16, sheet 01)

22.1.5.3. Testing
Inspection checkout forms shall require following tests for data to be recorded.
a. Grounding
1. Switchgear and MCC grounding system shall be tested for electrical and mechanical
continuity and results recorded.
2. Ground path resistance from each equipment ground bus to ground or grounding
electrode shall be measured and recorded.
WA shall verify
b. Metering and relay devices shall be tested in accordance with:
1. Appropriate primary and secondary injection relay test certificates (GOC form WH
E12).
2. Vendor instructions.
3. Procedures in clause 22.1.18 as applicable.
WA shall verify
c. Insulation resistance
1. Insulation resistance of main bus section shall be measured.
2. Sensitive equipment shall be disconnected and control wiring shall not be subjected to
bus test voltages.
3. Insulation resistance shall be performed before dielectric withstand voltage test and
before equipment is energised.
4. Test voltages and minimum acceptable resistance are in Table 7.
WA shall verify

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Table 7 - Minimum acceptance insulation resistance

Switchgear or MCC Test voltage Minimum insulation


voltage rating resistance
(volts) (megohms)
600 1 000 10
5k 5 000 200
15 k 5 000 200

d. Dielectric withstand voltage test


1. Dielectric withstand voltage test (pressure test) shall be performed on each bus
section (as applicable) between phases and phase to ground, in accordance with
following:
a) Current transformer secondaries shall be shortcircuited for test.
b) Voltage transformers shall be disconnected by removal of primary and
secondary fuses for test.
c) One pole of testing supply shall be grounded and bonded to frame of assembly
for phase to ground portion of test.
2. LV switchgear (600 V) test values shall not exceed 75% of maximum values in
Table 8 (refer to ANSI/IEEE C37.20, section 5.5).

Table 8 - AC LV switchgear (voltage and insulation levels)

Voltage and insulation levels for AC LV switchgear


Rated maximum voltage Insulation levels Reference DC withstand
(rms) low frequency AC withstand (kV)
(kV rms)
600 2,2 3,1
Note: Table 7 contains minimum acceptable insulation resistance.

3. MV switchgear (1 000 V or greater) test values shall exceed 75% of maximum values
in Table 9 (refer to ANSI/IEEE C37.20.2, section 5.5).

Table 9 - AC MV switchgear (voltage and insulation levels)

Voltage and insulation levels for MV switchgear


Rated maximum Insulation levels Impulse Reference DC
voltage low frequency AC withstand withstand
(kV rms) withstand (kV) (kV)
(kV rms)
4,76 19 60 27
15 36 95 50
38 80 150 *

4. Repeat step a.
5. After tests are complete, service cables shall be reconnected, fuses shall be replaced,
and shorting links (jumpers) shall be removed.
WA shall verify
6. Applicable tests of protective relaying and meter circuitry shall be performed in
accordance with clause 22.1.18 using primary and secondary injection methods as
appropriate.
WA shall verify

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7. Closing and tripping supply voltages shall be measured and recorded.


WA shall verify
8. Phase tests for switchgear or MCC
a) Switchgear or MCC shall be energised and correct phase rotation shall be
verified.
b) Phase sequence across tie circuit breaker to normal bus (Bus A) and emergency
bus (Bus B) shall be verified as applicable.
WA shall perform test
9. Bus duct tests
a) Tests shall be performed before final end connections are made up and covers
are assembled.
b) Insulation resistance of each run (phase to phase and phase to ground) shall be
measured.
c) Each phase to ground shall be tested with other two phases grounded, and then
each phase shall be tested to other two phases.
d) Test values shall comply with Table 10.
WA shall verify

Table 10 - AC bus duct DC test voltage levels

AC bus duct voltage rating DC test voltage


150 to 600 1 000
601 to 5 000 2 500
Above 5 000 5 000

e) If required, DC overpotential test shall be performed on each run (phase to phase


and phase to ground) in compliance with Table 11.
WA shall verify

Table 11 - AC bus duct overpotential (hipot) test voltage levels

Overpotential (hipot) test voltage


AC rated (kV rms) DC test voltage (kV)
5 20,0
15 37,5
35 55,0

f) Test results shall be evaluated and recorded on pass/fail basis by slowly raising
test voltage to required value, holding final test voltage for 1 minute, then slowly
reducing test voltage to zero.

22.1.5.4. Certification
a. Approved Contractor switchgear and MCC bus insulation and phasing test certificate
(GOC form WH EE2, sheets 01 and 02), as required, shall be completed and endorsed by
WA to record testing results and confirm that requirements of clauses 22.1.5 and 22.1.14
for equipment in hazardous locations, if applicable, have been performed satisfactorily.
b. Originals of test certificates from clause 22.1.18 for protective relays and metering
circuitry, if applicable, shall be attached to switchgear bus insulation and phasing test
certificate (GOC form WH EE2, sheet 01).
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c. Inspection checkout forms 22.6 and 22.8 shall be attached to appropriate certification
forms as detailed in clause 22.1.5.2.c.
d. Inspection checkout form 22.7 shall be attached to approved Contractor general test
certificate (GOC form WH EE16, sheet 01).

Note: See forms 22.7 and 22.8 for megger and bus phasing test
that WA is required to perform.

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Form 22.6 - Electrical switchgear inspection checkout

ELECTRICAL SWITCHGEAR SLD No SHT of


INSPECTION CHECKOUT (Procedure 22.1.5)
DATE: JOB NO: LOCATION: MODULE:
TAG NO. SYSTEM VOLTAGE Initials/Date
1. Remove shipping supports. Retain and tag items required for future maintenance. 1
2. Check phasing of bus connections prior to assembly. 2
3. Check and inspect for completeness of components. 3
4. All devices, such as monitoring equipment, ground fault relays, voltmeters, ammeters, 4
breakers, and indicating light bulbs, are installed as shown on equipment drawings.
5. Inspect control wiring, especially field connections at shipping splits, for tightness. 5
Ensure terminations are complete per applicable drawings.
6. Buses should have Insulation resistance test and DC proof test per clause 22.1.5.3. 6
7. Control and potential transformer primary windings should have insulation resistance 7
test.
8. Verify control transformer fuses, type, and size per drawings. 8
9. Verify potential transformer fuses, type, and size per drawings. Verify correct 9
functioning of drawout disconnecting and grounding contacts.
10. Check primary and secondary ratings of transformers including control transformers 10
per drawings and bill of material.
11. Check for proper equipment grounding (earthing) connections at both ends of 11
assembly.
12. Check ground (earth) bus bar continuity and ensure connection has been made at 12
shipping split points and properly tightened.
13. See that nameplates and device tags are complete and correct. 13
14. Cubicles clean, dry, and dust free. Proper drawings mounted on inside of cubicle 14
doors as required by code.
15. Space heaters are connected and operable, including thermostat controls. 15
16. Terminals and connections tight and secure. 16
17. Main bus and taps sized per Vendor drawings. 17
18. Insulation resistance test DC and AC controls circuits, with main and outgoing control 18
disconnect devices open. (Caution: check electronic device limitations for
application of test voltages.)
19. Check incoming power cables with insulation resistance test prior to connection to 19
switchgear (see clause 22.1.4.4).
20. Check DC High Potential Testing Data records for incoming power cables (see clause 20
22.1.4.4).
21. Ensure incoming feeder terminations properly made up after cable insulation tests are 21
completed.
22. Vendor provided service and supervision for this equipment. Vendor certified test 22
reports shall be attached to this inspection report.
23. Final inspection complete. Punch list items cleared (see certificate required). 23
24. Verify protective relay testing requirements per clause 22.1.18, as applicable. 24
REMARKS

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Form 22.7 - Motor control centre inspection checkout

MOTOR CONTROL CENTER SLD No SHT of


INSPECTION CHECKOUT (Procedure 22.1.5)
DATE: JOB NO: LOCATION: MODULE:
TAG NO: VOLTAGE: INITIAL/DATE
1. Inspect assembly for damage and missing parts. Remove shipping blocks and 1
supports. Retain and tag items required for future maintenance. Check bill of
materials for tools and spare parts and instruction books.
2. All changes recorded for as built drawings complete with initials of author. 2
3. Inspect bus taps and torque connection bolt joints per Vendor specifications. 3
4. Check equipment nameplate data in accordance with Vendor drawings and per 4
job specifications.
5. Check for correct ratings of circuit breakers, switches, fuses, contactors, 5
protective relays, other components against one line diagrams and Vendor
drawings.
6. Inspect equipment grounding connections and conductor sizes, including internal 6
grounds for plugin units.
7. Megger main bus, phase to phase and phase to ground, per clause 22.1.5.3. 7
8. Check phase sequence across tie breaker connected between normal bus and 8
emergency bus or Bus A and Bus B as appropriate. (Verify before buses are
energised.) **
9. Check that overload reset buttons are functional on each starter. ** 9
10. Run insulation resistance test on AC controls circuits, with main and outgoing 10
control disconnect devices open (Caution: check electronic device limitations).
(See clause 22.1.4.4)
11. Run insulation resistance test on incoming power cables prior to connection to 11
switchgear (See clause 22.1.4.4).
12. Ensure incoming feeder terminations properly made up, after cable insulation 12
tests are completed.
13. Perform manual operation of breakers, switches, and contactors in accordance 13
with Vendor instructions.
14. Ensure three phase colour coding for connections and phasings are in 14
accordance with drawing colour code requirements.
REMARKS

** WA shall perform test

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Form 22.8 - Bus duct inspection checkout

BUS DUCT SLD No SHT of


INSPECTION CHECKOUT (Procedure 22.1.5)
DATE: JOB NO: LOCATION: MODULE:
INITIAL/DATE
1. Inspect entire assembly, including auxiliary equipment, for apparent damage or 1
missing parts. Check bill of materials for tools and spare parts and Instruction
books.
2. Remove shipping blocks and supports. Retain and tag items required for future 2
maintenance (such as drain fittings, cover parts, spray paint, or taping supplies).
3. Torque bus segment connections in accordance with Vendor 3
recommendations. Note: Bus insulation tests shall be completed prior to bolting
connectors at either end or applying grounding (earthing) connections.
4. Check that rain holes are unplugged. See Vendor drawings and instructions. 4
5. Check that gaskets are installed (if required). Check that wall and vapour sealoffs 5
are properly installed in accordance with installation drawings.
6. Megger test bus and record on field inspection record. See clause 22.1.5.3. 6
7. Check for proper phasing after installation, but prior to energising loads. ** 7
8. Connect space heaters and check operability (as applicable), including 8
temperature controls. Note: Heater circuit cables shall be megger tested first.
REMARKS

** WA shall verify.

22.1.6. Circuit breakers - air, moulded case, vacuum, and oil immersed

22.1.6.1. General
Vendor test specifications shall be consulted as applicable.
a. Following inspection and test procedures in clauses 22.1.6.2 and 22.1.6.3 shall be
applicable to circuit breakers in metal clad switchgear, MCC, or dedicated enclosures.
b. Following shall be performed after clause 22.1.5 is completed to allow main bus and
control circuits to be safely energised.

22.1.6.2. Inspection
a. Before installation
1. Before installation checks in clause 22.1.5 shall be performed to ensure required
materials and parts have been accounted for and installed.
2. Maintenance devices for servicing and operating circuit breakers in accordance with
Vendor instructions shall be available.

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3. Auxiliary equipment, materials, and spare parts shipped separately shall be identified
and verified in accordance with shipping documents.
b. Inspection checkout form 22.9 can assist in acceptance of Contractor circuit breaker low
and medium power test certificate (GOC form WH EE3, sheets 01, 02, or 03).
Inspection checkout for drawout circuit breakers needs to be completed before final
tests in GOC form WH EE3, sheet 01, 02, or 03.
c. Testing for low and medium power circuit breakers shall be completed on each drawout
breaker and trip unit before being placed in service.
WA shall verify
d. After installation and after breakers have been inspected and tested in accordance with
form 22.9 checkout sheet, following mechanical operation checks shall be performed:
1. Breaker stab or cluster connections to power bus shall have correct cell fit and contact
alignment for in service positioning.
WA shall verify
2. Main and secondary plug and socket connectors for control or interlocking circuits
shall have correct alignment and connection.
3. Bus shutters and energy isolation mechanism shall operate correctly.
4. Special grounding features for breaker frame shall have correct fitting and operation.
5. Moving current carrying parts and sliding surfaces shall have proper lubrication.
6. Circuit breaker close and trip mechanism operation shall be manually and electrically
checked.
WA shall verify steps 1 through 6 above
7. Operation of local and remote mechanical and electrical interlocks and trip systems
(including functions of selector switches) shall be checked.
WA shall verify
Some power breakers may not be drawout type. All breakers, including moulded
case types, require mechanical operation checks using form 22.9 drawout checkout
list for guidance.
8. Appropriate requirements in clause 22.1.14 for hazardous locations shall be met.
WA shall verify
9. Grounding switch, if part of circuit breaker assembly, shall be checked.
WA shall verify
10. Control and communication terminals are securely wired.
WA shall verify
11. Cable and bus connections
a) Tightness of cable and bus connections shall be verified with calibrated torque
wrench in accordance with Vendor data.
b) In absence of Vendor data, bolt torque values in Table 4 shall be used.
WA shall verify
12. Arc chute alignment and grounding shall be checked.
WA shall verify

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22.1.6.3. Testing
a. Low voltage (moulded case) breakers
1. Refer to NETA chapter 7.6.1 for testing guidelines.
2. Following tests shall be performed (as required) in accordance with approved
Contractor moulded case breaker test report (GOC form WH EE3, sheet 02).
3. Contact resistance shall be measured and compared to adjacent poles and similar
breakers.
4. Deviations of more than 50% shall be investigated.
5. Time and current characteristic tests shall be performed by passing 300% rated
current through each pole separately, unless breaker is equipped with ground fault
protection (GFP). See Vendor for test method of breakers with built in GFP.
6. Trip times shall comply with values in Table 12.
WA shall verify

Table 12 - Moulded case breaker overcurrent trip test

Overcurrent trip test


(300% of rated continuous current of breaker)
Trip time (s)
Minimum Maximum
Voltage Range or rated Thermal Magnetic Maximum Maximum trip
continuous breakers breakers time for cable
current (Amps) protection
600 15 to 45 5 5 80 100
600 50 to 100 5 5 150 200
240 110 to 225 10 5 200 300
600 110 to 225 10 - 200 300
600 250 to 450 25 - 250 300
600 500 to 600 25 10 250 350
600 700 to 1 200 25 10 450 600
600 1 400 to 2 500 25 10 600 750
Note: Values are based on tests on conductors in conduit by circuit breaker Vendors (NEMA reference).

7. Pickup current
a) Instantaneous pickup current shall be determined by pulse method.
b) Clearing times should be within four cycles.
c) Instantaneous pickup current levels should be within 20% of Vendor published
values.
WA shall verify
8. Insulation resistance
a) Insulation resistance tests shall be performed pole to pole, across open pole, and
each pole to ground.
b) Test voltage shall be 1 000 VDC.
WA shall verify
b. Low voltage air breakers
1. Refer to NETA section 7.6.1 for testing guidelines.

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Use if GOC form WH EE3, sheet 01 assists in the realisation of certification.


2. Tests in 3. through 11. shall be performed as required by BP.
3. Contact resistance
a) Contact resistance shall be measured.
b) Resistance values greater than 200 micro ohms or any value deviating from
adjacent poles or similar breakers more than 50% should be investigated.
WA shall verify
4. Insulation resistance
a) Insulation resistance tests shall be performed from pole to pole, each pole to
ground, and across open contacts of each phase at 1 000 VDC.
b) Insulation resistance shall be at least 50 megohms.
5. Minimum pickup current shall be determined by primary current injection.
WA shall verify
6. Long time delay shall be determined by primary injection at 300% of pickup current.
WA shall verify
7. Short time pickup and time delay shall be determined by primary injection at intended
settings in accordance with specifications.
WA shall verify
8. Instantaneous pickup current shall be determined by primary injection.
WA shall verify
9. Trip unit reset characteristics shall be verified by test in accordance with Vendor
instructions.
WA shall perform test
10. Auxiliary protective devices, such as ground fault or undervoltage relays, shall be
activated and operation of shunt trip devices simulated to verify operation.
WA shall perform test
11. Minimum pickup current
a) Minimum pickup current, trip times, and instantaneous pickup values shall be set
in accordance with settings reflected by IFC data sheets.
b) Test values shall fall within Vendor published time and current characteristic
tolerance band for settings and curves as applicable.
WA shall perform test
c. Medium voltage air breakers
1. Refer to ANSI/IEEE C37.09 and NETA 7.6.1.3 for testing guidelines.
Use if GOC form WH EE3, sheet 03 assists in the realisation of certification.
2. Tests in 3. through 8. shall be performed as required by BP.
3. Contact resistance
a) Contact resistance shall be measured.
b) Resistance shall not exceed 500 micro ohms.
c) Vendor recommendations may be consulted for acceptable range.
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WA shall verify
4. Minimum pickup voltage tests on trip and close coils shall be performed with
calibrated voltmeter and adjustable source. Record results on data sheet.
WA shall perform test
5. Circuit breaker shall be tripped by simulated operation of each protective device.
WA shall perform test
6. Insulation resistance
a) Insulation resistance test pole to pole, pole to ground, and across open contacts
of each phase shall be performed.
b) 2 500 VDC megger shall be used.
WA shall verify
7. Insulation resistance of control wiring
a) Insulation resistance test on control wiring at 1 000 VDC shall be performed.
b) Electronics shall be isolated as necessary in accordance with Vendor
instructions.
WA shall verify
8. Overpotential tests
a) Overpotential test or power factor test with breaker in open and closed position
shall be performed.
b) Power factor and arc chute watt loss shall not exceed Vendor allowable values.
c) See Table 9 for overpotential test voltages.
WA shall verify
d. Medium voltage oil breakers
1. Refer to NETA 7.6.2.1 for testing guidelines.
Use if GOC form WH EE3, sheet 04 assists in the realisation of certification.
2. Tests in 3. through 7. shall be performed as required by BP.
3. Contact resistance
a) Contact resistance on each breaker pole shall be measured.
b) Contact resistance shall not exceed 500 micro ohms.
WA shall verify
4. Insulation resistance test pole to pole, each pole to ground, and across open contacts
of each phase shall be performed.
WA shall verify
5. Overpotential test
a) Overpotential test or power factor test with breaker in open and closed position
shall be performed.
b) Power factor and arc chute watt loss shall not exceed Vendor allowable values.
c) See Table 11 for overpotential test voltages. Also refer to NFPA 70B.
WA shall verify
6. Oil tests
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a) Oil samples shall be drawn.


b) Dielectric strength tests shall be performed.
c) Dielectric strength of each sample shall not be less than 26 kV as tested with
2,5 mm (0,1 in) gap in accordance with ANSI/IEEE Standard C57.106.
WA shall verify
7. Circuit breaker shall be tested by manual or electrical tripping of each protective
device.
WA shall perform test
e. Medium voltage vacuum breakers
1. Refer to ANSI/IEEE C37.09 for testing guidelines.
2. Tests in 3. through 9. shall be performed as required by BP.
3. Contact resistance
a) Contact resistance shall be measured.
b) Resistance shall not exceed 500 micro ohms.
c) Vendor recommendations for acceptable range shall be consulted.
WA shall verify
4. Minimum pickup voltage tests on trip and close coils shall be performed.
WA shall verify
5. Circuit breaker shall be tripped by operation of each protective device.
WA shall perform test
6. Insulation resistance test pole to pole, pole to ground, and across open contacts of
each phase shall be performed.
WA shall verify
7. Insulation resistance test on control wiring at 1 000 VDC shall be performed.
WA shall verify
8. Overpotential tests
a) Overpotential tests with breaker in open and closed position shall be performed.
b) Test voltages in accordance with Vendor recommendations shall be applied.
WA shall verify
9. Vacuum bottle tests
a) Vacuum bottle integrity (overpotential) test shall be performed across each
vacuum bottle with switch in open position in strict accordance with Vendor
published data.
b) Adequate barriers and protection against X-rays shall be provided during test.
c) Test shall not be performed unless contact displacement of each interrupter is
within Vendor tolerance.
d) Maximum voltage stipulated for test shall not be exceeded, and it should be
noted that some high potential test sets are half wave rectified and may produce
peak voltages in excess of switch Vendor recommended maximum.
WA shall verify

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22.1.6.4. Certification
Following applicable approved Contractor forms shall be completed and endorsed by WA to
record results of testing and confirm that requirements of procedures in clauses 22.1.6 and
22.1.14 (as applicable) have been performed satisfactorily:
a. Circuit breaker test form for low voltage power circuit breakers (GOC form WH EE3,
sheet 01).
b. Moulded case breaker test report (GOC form WH EE3, sheet 02).
c. Medium voltage circuit breaker test certificate (GOC form WH EE3, sheet 03).
d. High voltage limited oil interrupter test report (GOC form WH EE3, sheet 04).
e. Originals of test certificates generated in clause 22.1.18 for protective relays and metering
circuitry and shall be attached to forms listed in a. through b. above.
f. Inspection checkout form 22.9 shall be attahed to certification forms listed in a. above.

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Form 22.9 - Drawout air circuit breaker inspection checkout

DRAWOUT AIR CIRCUIT BREAKER SLD No SHT of


INSPECTION CHECKOUT (Procedure 22.1.6)
DATE: PROJECT NO: LOCATION: MODULE:
TAG NO: __________________________________________________ INITIAL/DATE
(See other instructions for manually operated breakers.)
One at a time, mount breakers on drawout rails in respective cubicles, turn on unit control
power source, and check following:
1. Roll breaker into test position. Spring charging mechanism should engage to charge closing 1
spring (for electrically operated mechanisms).
2. Withdraw breaker to disconnect position. (Note: Closing spring may discharge when this is 2
done.) Check to see if door will close and latch as it should.
3. Roll breaker into test position. Close and trip breaker using door switch and check indication 3
light for operation. If breaker is equipped with remote control switch, verify function for both
remote and local positions. Operate breakers from remote controls switch or interlock, as
required. Close breaker from remote control station as applicable, using local/remote switch
set to remote.
4. Trip breaker and check indication light. Trip from door switch and remote control station. ** 4
5. Trip each breaker from each protective device and check relay targets for operation. Test 5
proper operation of lockout device in closing circuit. **
Note: Observe Vendor instructions on limiting consecutive close operations.
6. Trip each breaker with its mechanical trip device. ** 6
7. Check cell fit, contact alignment, and wipe clean (air break only). 7
8. Perform insulation resistance test (megger) between each phase and across open pole to frame 8
and ground with breaker withdrawn. Repeat test between each phase with breaker closed.
Record below. Ground poles not being tested.
9. Perform contact resistance test and record below. 9
10. Roll breaker into connected position and test operation of latch check switch, if provided, and 10
verify control interlocks are operable.
11. Verify nameplate data is in accordance with Vendor drawing (continuous amperes, interrupting 11
amps, insulation resistance, contact resistance).
Insulation resistance: A to G B to G (closed) C to G
(closed) (closed)
A B C AA to A BB to B (open) CC to C
AA BB CC (open) (open)
A to B B to C C to A
Contact resistance (micro ohms): A B C
Notes:
1. This inspection and test checkout is required for every drawout breaker installed in operating assembly.
2. See certificate required circuit breaker, low and medium power test certificate (GOC form EE3, sheets 01, 02, or 03).
3. See other instructions for vacuum breakers in clause 22.1.6.3.e.
** WA shall perform test.

22.1.7. Contactor starters

22.1.7.1. General
a. Following inspection and test procedures in clauses 22.1.7.2 and 22.1.7.3 shall be
applicable to contactor starters in metal clad switchgear, MCC, or dedicated enclosures.
b. This clause shall be performed after clause 22.1.5 tests are completed such that main bus
and control circuits can be safely energised.

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22.1.7.2. Inspection
a. Before installation (after shipping inspection)
1. Packing material, including silica gel, taping, and binding materials from moving
parts or assemblies, shall be removed from contactors.
2. Enclosures shall be cleaned and inspected.
3. Damage, if any, shall be repaired.
4. Parts, devices, instructions, and special tools required for assembling equipment or
for installation in assigned enclosures shall be located and inspected.
b. After installation
1. Unit descriptions shall be compared with IFC data sheets and Vendor drawings for
accuracy.
2. Isolating switch:
a) Shall be capable of being padlocked in off position.
b) Operating handle shall be mechanically interlocked with door.
3. Operation of isolator and any auxiliary switches or contacts mounted with isolator
shall be inspected and checked for proper function.
4. For drawout or plugin starters, fit of withdrawal unit and alignment of main and
auxiliary circuit contacts (including plugin mains) shall be inspected.
5. Mechanical operation of contactors and relays, including alignment of moving
contacts, shall be verified.
6. Main and control fuse ratings shall be compared for accuracy with drawings and fuse
tables in equipment specifications.
7. Internal wiring shall be inspected for security to ensure that it cannot be caught or
damaged by door or drawout unit.
8. Door shall be bonded to enclosure and enclosure shall be properly grounded.
9. Position and operation of control switches, lamps, and pushbuttons shall be correct.
10. Lens colours shall comply with code.
11. Ammeters and scales shall be correct and suitable.
12. Space heaters, if required, shall:
a) Be in correct position and not too close to internal wiring or heat sensitive
devices.
b) Have correct voltage and wattage ratings.
13. Arc chutes, phase separators, and other insulating components shall be clean and in
good condition.
14. Applicable requirements of clause 22.1.14 for equipment in hazardous locations shall
be satisfactorily performed.
15. Associated field equipment shall be inspected and subject to approval.

22.1.7.3. Testing
a. Test overloads and trip time
1. Overload test should be performed at 300% of motor full load current.
2. Trip times shall be in accordance with Vendor tolerances.
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3. Results shall be recorded on approved Contractor contact starter test form (GOC form
WH EE4, sheet 01).
WA shall verify
b. Overload relay
1. Overload relay shall be tested for single phasing by passing 80% of full load current
through two phases only.
2. Results shall be recorded on approved Contractor motor thermal overload relay test
form (GOC form WH EE4, sheet 02).
WA shall verify
c. Ammeter calibration
1. Calibration of local or remote ammeters shall be tested by primary injection.
2. Secondary injection shall only be used for circuits outside range of primary injection
sets.
3. Results shall be recorded on approved Contractor contact starter test form (GOC form
WH EE4, sheet 01).
WA shall verify
d. Starter insulation resistance shall be tested with results recorded as follows:
1. Power wiring
a) Test voltage shall be 1 000 volts.
b) Minimum value shall be 10 megohm.
c) Technique shall be same as clause 22.1.4.2.b.3.
2. Control wiring
a) Test voltage shall be 500 volts.
b) Minimum value shall be 5 megohm.
c) Electronic devices shall be isolated in accordance with Vendor instruction.
WA shall verify
e. Control circuits
1. Control circuit operations and indications shall be tested from local and remote
locations.
2. Indications from local and remote locations shall be verified.
3. Breaker status remote indicator shall be verified during control circuit testing.
WA shall perform test
f. Protective relays and meters
1. Protective relays or meter circuitry shall be tested in accordance with clause 22.1.18,
as applicable.
2. Results shall be recorded on approved Contractor contact starter test form (GOC form
WH EE4, sheet 01).
WA shall verify
g. Certified test certificates, if available for tests performed by Vendor:
1. Shall have original Vendor test certificates added and remain in Vendor dossier.

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2. Shall either:
a) Have copies of certificates, if available for tests performed in Vendors works,
attached to approved Contractor contact starter and motor thermal overload test
forms (GOC form WH EE4, sheets 01 and 02).
b) Be identified as being performed with comments in appropriate I&T summary
that defines minimum inspection and test requirements against requirements of
approved Contractor contact starter test form (GOC form WH EE4, sheet 01).
h. If Vendor testing in g. was not performed, following shall be performed:
1. Thermal overloads and ground fault relays shall be checked against starter tabulations
to ensure that installed relays have correct setting range and set point adjustments.
2. Setting range and set point shall be recorded on approved Contractor contact starter
test form (GOC form WH EE4, sheet 01) in overload trip setting column.
3. If changes to overloads have been made or markings have been lost, complete retest
shall be performed.
4. Other than 3., sample points may be performed to ensure device is still within Vendor
tolerances.

22.1.7.4. Certification
a. Approved Contractor contact starter and motor thermal overload relay test forms (GOC
form WH EE4, sheets 01 and 02) shall record test results and endorsed to confirm that
requirements of this clause (and clause 22.1.14 for equipment in hazardous locations, if
applicable) have been performed satisfactorily.
b. If applicable, results of drying motor windings (see clause 22.2.12), shall be attached to
approved Contractor contact starter and motor thermal overload relay test forms (GOC
form WH EE4, sheets 01 and 02), together with certificates generated by implementing
procedures in clause 22.1.18 for protective relays and metering circuits.
c. Originals of test certificates generated in clause 22.1.18 shall be attached to approved
Contractor contact starter test form (GOC form WH EE4, sheet 01).
Contractor contact starter test form GOC WH EE4, sheet 01, shall verify that
contactor and starter circuit (including remote field equipment forming part of
circuit) are installed and tested satisfactorily.

22.1.8. Medium voltage air switches

22.1.8.1. General
a. Following inspection and test procedures in clauses 22.1.8.2 and 22.1.8.3 shall apply to
medium voltage air switches in metal clad switchgear or dedicated enclosures.
b. Procedures in clause 22.1.5 shall be performed first to ensure that main bus and control
circuits can be safely energised.

22.1.8.2. Inspection
a. Before installation
1. Nameplate ratings and instructions
a) Nameplate ratings of air switch shall compare properly with approved drawings.
b) Special instructions for switch installation shall be checked.
2. Transit packing materials shall be removed from air switch.
3. Air switch unit shall be correctly labelled.
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4. Interior of unit shall be cleaned and silica gel drying agents shall be removed.
5. Shipment shall be verified to ensure it includes necessary field assembly parts and
detail items.
b. After installation
1. Testing guidelines shall be in accordance with:
a) ANSI/IEEE C37.34.
b) NETA 7.5.1.2.
2. Equipment in fuse switch compartment and air switch compartment shall be inspected
for damage during installation.
3. Switch unit shall be mounted level and plumb.
4. Necessary repairs shall be performed if damaged.
5. Bus connections shall be properly torqued.
6. Required area clearances shall be verified.
7. Mechanical operation
a) Air switch shall properly operate mechanically.
b) Required mechanical or key interlocks shall be properly installed in air switch
cubicle or cover.
c) Equipment lockout mechanism shall operate properly.
d) Moving current carrying parts and sliding surfaces shall be properly lubricated.
8. External wiring shall be checked for proper electrical interlocks, remote indications,
and electric space heater power, as applicable.
9. Interlocking systems shall be tested for correct operation and sequencing.
10. Alignment
a) Contact alignment of air switch, blade penetration, travel stops, latching
mechanisms, and mechanical operation of on/off indicator shall be checked.
b) Required adjustment checks shall be performed in accordance with Vendor
instructions.
11. Necessary operating handles shall be provided and properly stowed or retracted. If
retractable type handle, verify it retracts properly.
12. Necessary grounding bus and cables shall be properly installed and connected.

22.1.8.3. Testing
a. Insulation resistance
1. One minute insulation resistance shall be measured through closed switch (phase to
phase and each phase to ground) and pole to pole across open switch.
2. Megger voltage shall comply with clause 22.1.5.3.
WA shall verify
b. Contact resistance
1. DC contact resistance shall be tested across each switch blade (closed), as stipulated
by BP.
2. Value exceeding 50 micro ohms or values that deviate from adjacent poles or similar
switches by more than 50% shall be investigated.
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WA shall verify
c. After switch testing is complete, bus connections and mechanical throat alignment from
switch to load (i.e., transformer) shall be properly made up.
WA shall verify
d. Protective relays and meters
1. Associated protective relays and meter circuitry shall be tested in accordance with
clause 22.1.18.
2. Internal current transformers, if supplied, shall be tested and have ratings verified in
accordance with testing of MV switchgear current transformers.
e. Applicable requirements of clause 22.1.14 for equipment in hazardous locations shall be
performed.
f. Correct MV fuses shall be available in accordance with circuit requirements on approved
drawings.

22.1.8.4. Certification
a. Approved Contractor medium voltage air switch inspection form (GOC form WH EE5,
sheet 01) shall be used to record results of testing and shall be endorsed to confirm that
requirements in clauses 22.1.8 and 22.1.14, if applicable, have been performed
satisfactorily.
b. Original test certificates generated in clause 22.1.18 for protective relays and metering
circuits shall be attached to approved Contractor medium voltage air switch inspection
form (GOC form WH EE5, sheet 01).

22.1.9. Power transformers - oil filled and dry type

22.1.9.1. General
Following inspection and test procedures in clauses 22.1.9.2 and 22.1.9.3 shall apply to oil filled
and dry type power transformers.

22.1.9.2. Inspection
a. Before installation (oil filled and dry type)
1. Unit shall be inspected for physical damage, including dents or scraped paint.
2. If unit is shipped with impact recorder, data shall be checked before transformer is
unloaded.
3. Equipment certification shall comply with area and specification requirements.
4. Nameplate data and information on special attachments or auxiliary devices shall be
checked and compared with approved drawings.
b. After installation (oil filled)
1. Initial inspection
a) Transformer and auxiliary equipment shall be inspected for alignment and
tightness of anchor bolts and fasteners.
b) Installation and weatherproofing of primary, secondary, and auxiliary terminal
boxes shall be checked.
c) Auxiliary device (fans, pumps, sudden pressure device, indicators, tap changer,
and gas pressurisation system) operation shall be verified.
d) Items on inspection checkout sheets shall be completed as indicated.
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2. Lockout provisions for unit mounted disconnect switches and tap change shall be
checked.
3. Grounding
a) Grounding (earthing) pads and grounding connections to ground grid shall
comply with installation drawings.
b) Bolts, cable size and type, and connectors shall be proper type, size, and
correctly installed.
4. X connection
a) X connection shall be inspected.
b) Neutral grounding resistors, if installed, shall comply with clause 22.1.11.
c) If resistors are not installed, grounding cable or straps from X to grid shall
comply with specifications.
5. Oil filled transformers
a) Proper oil level at ambient temperature shall be checked.
b) Gasketed covers, radiator flanges and plugs, and auxiliary devices shall be
checked for leaks or seepage.
6. Tank pressure
a) Tank pressure and vacuum relief device, if supplied, shall be checked.
b) Inert gas alarm device (i.e., nitrogen regulator for tank pressure), if used, shall be
checked.
7. Mechanical pressure relief device (required on oil filled units) shall be checked.
c. After installation (dry type)
1. Initial inspection
a) Nameplate ratings of transformer and special instructions concerning auxiliary
equipment shall be checked and compared with those on approved drawings.
b) Transformer shall be inspected for internal damage.
2. Equipment certification shall comply with area and specification requirements.
3. Auxiliary devices, such as fans, indicators, and tap changer, shall be checked for
compliance with specifications.
4. Electrical connections
a) Tightness of accessible bolted electrical joints shall be checked with calibrated
torque wrench for compliance with Vendor published data.
b) In absence of Vendor data, bolt torque values in Table 4, located in
clause 22.1.4, shall be used.
5. Clear space requirements for proper cooling as provided on transformer nameplate
shall be checked with measured clearances as installed.
6. Switchgear connections
a) Tightness of bus bar connections and bracing from bushing terminals to bus bars
of switchgear shall be inspected.
b) Separation distances between high voltage cables for terminal box connections
shall be adequate.
c) Terminations shall comply with Vendor drawings and installation specifications.
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d. Inspection checkout (oil filled)


1. Inspection checkout form 22.10, sheets 1 and 2, shall be used to assist in acceptance
of test certificates.
2. Certificates shall be on approved Contractor transformer test form (GOC form WH
EE6, sheet 01 and sheet 03).

22.1.9.3. Testing
a. Testing (oil filled)
1. Alarm and trip circuits of protective devices on unit shall be tested.
WA shall verify
2. Cables shall be tested and certified in accordance with cable certificate as required in
clause 22.1.4 (see GOC form WH EE1, sheets 01 through 03).
WA shall verify
3. Ground continuity, X, resistor, and tank to ground grid shall be measured.
WA shall verify
4. Breakdown voltage tests
a) Breakdown voltage tests, if required, shall be performed on two oil samples
from each transformer and each barrel, container, or fraction thereof used to fill
transformer with oil.
b) Dielectric strength of each sample shall be at least 26 kV as tested with 2,5 mm
(0,1 in) gap in accordance with ANSI/IEEE C57.106.
WA shall verify
5. Insulation resistance
a) Insulation resistance for both HV and LV windings shall be measured by using
battery or motor operated megger.
b) Primary (HV) winding insulation to ground shall be tested with tank and
secondary (LV) winding grounded.
c) Secondary winding insulation to ground shall be tested with tank and primary
winding grounded.
d) Primary winding to secondary winding shall be tested.
e) Minimum acceptable insulation resistance (megohms) shall be 8 times kV rating
of winding under test.
f) Megger test voltages shall comply with values in Table 10 and shall be corrected
for ambient temperature in accordance with Table 13 (in clause 22.1.5).
g) After completing tests, terminals shall be grounded to fully discharge residual
current.
WA shall verify
6. Dielectric absorption test (if required)
a) Dielectric absorption test shall be performed winding to winding and winding to
ground for 10 minutes.
b) Polarisation index shall be computed.

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c) Test voltage and minimum acceptance values shall be corrected for ambient
temperature in accordance with Table 13 and shall comply with Vendor
recommendations.

Table 13 - Insulation resistance conversion factors for test temperature to 20C (68F)

Temperature Transformer
conversion factors
C F Oil Dry
0 32 0,25 0,40
5 41 0,36 0,45
10 50 0,50 0,50
15 59 0,75 0,75
20 68 1,00 1,00
25 77 1,40 1,30
30 86 1,98 1,60
35 95 2,80 2,05
40 104 3,95 2,50
45 113 5,60 3,25
50 122 7,85 4,00
55 131 11,20 5,20
60 140 15,85 6,40
65 149 22,40 8,70
70 158 31,75 10,00
75 167 44,70 13,00
80 176 63,50 16,00

d) Absorption test polarisation index should be above 2,0 unless scale value on
available test equipment prevents meaningful ratio.
WA shall verify
7. AC overpotential test (if required)
a) AC overpotential test shall be performed on high and low voltage windings to
ground.
b) AC high potential test voltage shall not exceed 75% of factory test voltage as
indicated in Table 14 for 1 minute duration.
WA shall verify

Note For high voltage insulation tests, regulated power supply


shall be used for test equipment. Variations in operating
power during test runs may result in exceeding
recommended high voltage limit.

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Table 14 - Overpotential test voltage for power and distribution transformers

Overpotential test voltage for power and distribution transformers


Nominal system voltage (1) Insulation class AC factory test (kV)
(kV) oil immersed (2)
1,2 1,2 10
2,4 2,5 15
4,8 5,0 19
8,32 8,7 26
14,4 15,0 34
18,0 18,0 40
25,0 25,0 50
34,5 34,5 70
46,0 46,0 95
69,0 69,0 140
Notes:
1. Intermediate voltage ratings shall be placed in next higher insulation class.
2. Also applies to silicone or other liquid immersed to comply with Vendor recommendations.

8. No load tap changer settings on transformers shall be set in accordance with engineer
instructions or on mid tap if not otherwise instructed.
WA shall verify
9. Power factor test results corrected to 20C (68F) should not exceed:
a) For distribution transformers up to 500 kVA: 1%.
b) For power transformers 500 kVA and above: 0,5%.
c) Bushing power factor (PF) tests results (hot collar or ungrounded) should be
within Vendor published tolerances.
10. Turns ratio test
a) Turns ratio test results (required for each tap position) should not deviate more
than 0,5% from calculated ratio.
b) All phases should correlate for each tap setting.
WA shall verify
b. Testing (dry types)
1. Refer to ANSI/IEEE C57.12.01 for test guidelines.
2. Insulation resistance
a) Insulation resistance for both HV and LV windings shall be measured by using
1 000 volt battery or motor operated megger.
b) Primary (HV) winding insulation to ground shall be tested with tank and
secondary (LV) winding grounded.
c) Secondary winding insulation to ground shall be tested with enclosure and
primary winding grounded.
d) Primary winding to secondary winding shall be tested.
e) Minimum acceptable insulation resistance (megohms) shall be eight times kV
rating of winding under test.

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f) Megger test voltages shall comply with values in Table 10 (in clause 22.1.5) and
shall be corrected for ambient temperature in accordance with Table 13.
g) Winding resistance should compare within 1% of adjacent windings.
WA shall verify
3. Dielectric absorption test (if required)
a) Dielectric absorption test shall be performed winding to winding and winding to
ground for 10 minutes.
b) Polarisation index shall be computed.
c) Test voltage shall comply with Table 10 and minimum acceptance values shall
be corrected for ambient temperature in accordance with Table 13 and shall
comply with Vendor recommendations.
d) Absorption test polarisation index should be above 2,0 unless extremely high
value is obtained at end of one such that additional time value will not yield
meaningful result with available test equipment.
WA shall verify
4. Turns ratio test (if required)
a) Turns ratio test (if required) shall be performed between windings for all tap
positions.
b) Final tap setting shall be determined by engineer.
c) Test results should not deviate more than 0,5% from calculated ratio.
d) Phase test data should agree.
WA shall verify
5. AC overpotential test (if required)
a) AC overpotential test shall be performed on high and low voltage windings to
ground.
b) AC high potential test voltage shall not exceed 75% of factory test voltage as
indicated in Table 15 for 1 minute duration.

Table 15 - Applied potential test voltage

Nameplate winding voltage rating Factory test potential


(VAC) (kVAC)
0 to 250 2,5
251 to 1,200 4,0
1,201 to 2,500 10,0
2,501 to 5,000 12,0
5,001 to 8,660 19,0
8,661 to 15,000 31,0

c) Results shall be evaluated on go/no go basis (refer to NEMA ST-20).


WA shall verify
6. Alternate to AC overpotential test (if required)
a) Alternate to AC overpotential test (if required) is insulation power factor test.
b) Test shall be performed from each winding to each other winding and from each
winding to ground.

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c) Power factor test values in excess of 3% should be investigated.


d) Test equipment shall be Doble type or equivalent.
7. Winding resistance tests, if required, shall be performed for each winding at full
turns.
WA shall verify

22.1.9.4. Certification
a. Approved Contractor transformer test forms (GOC form WH EE6, sheets 01 through 03)
shall be used to record test results and shall be endorsed to confirm that requirements in
clause 22.1.9 have been performed satisfactorily.
b. Following supplementary procedures should be completed as applicable:
1. Neutral grounding resistors in clause 22.1.11.
2. Oil testing transformer and link box in clause 22.1.15.
3. Protective relays and metering circuits in clause 22.1.18.
c. Procedures in b. shall generate following certificates:
1. Transformer and transformer turns ratio test forms (GOC form WH EE6, sheets 01
through 03).
2. Neutral grounding resistor test form (GOC form WH EE7, sheet 01).
d. Inspection checkout form 22.10, sheets 1 and 2, shall be attached to certification forms
listed in a. above.
WA shall verify

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Form 22.10 - Liquid filled transformer inspection checkout (sheet 1 of 2)

LIQUID FILLED TRANSFORMER SLD No SHT 1 of 2


INSPECTION CHECKOUT (Procedure 22.1.9)
DATE: JOB NO: LOCATION: MODULE:
TAG NO: __________________________________________________ INITIAL/DATE
1. Receiving operations and inspection complete, including required auxiliary items shipped 1
with ordered unit. Verify items per packing list.
2. Verify tag number, HV/LV ratings, and kVA rating to comply with plant drawings and 2
one line diagram.
3. Check transformer nameplate against purchase order and specifications. 3
4. Verify location, mountings. and bushing orientation to comply with drawings. 4
5. Visually inspect for cleanliness. No chips, cracks, or other apparent damage to bushings, 5
radiators, tanks, primary terminal enclosure, and switch enclosure. Paint scuffs or
scratches shall be repaired with approved methods and materials.
6. Check lubrication and freedom of operation and rotation of cooling fans. 6
7. Check lubrication and freedom of motion of no load tap changers and control 7
accessories.
8. Inspect fuses, disconnect switches, and lightning arrester installations as required. 8
9. Inspect for liquid leakage around tank, radiators, valves, fittings, accessories, and other 9
welded or bolted joints under oil. Report required action.
10. Collect samples of insulating liquid in accordance with Vendor instructions and verify 10
dielectric strength of insulating liquid. Take laboratory samples for complete analysis of
insulating liquid.
11. Check for nameplate winding continuity between bushings. 11
12. Verify neutral wire size, insulation, and colour compliance with drawings or schedule. 12
13. Verify case ground (and grounding resistor if required) is correctly installed. Measure 13
bonding resistance of connections and record on test certificate.
14. Check that incoming feeders have insulation resistance tests performed and verify test 14
data as acceptable.
15. Check inert gas pressure gage (pressure should be in accordance with Vendor 15
instructions), and verify pressure relief settings.
16. Check temperature gage for proper operation. 16
17. Check liquid level gage for proper operation and proper level of liquid in oil filled 17
compartments.
18. Verify space heaters are connected and operable, including thermostat controls, if 18
applicable.
19. Measure primary and secondary voltages with tap changer in each position and verify 19
that voltage ratios comply with transformer nameplate. Apply 480 V construction power to
transformer primary (HV) connections and measure secondary (LV) voltages. Primary
voltage rating shall not be exceeded.
20. Record transformer tap setting below. Set at mid tap unless otherwise directed. 20
21. Check sudden pressure relay and connections (if supplied). 21

22. Verify alarm and control circuits as connected and complete. Verify alarm, trip, and fan 22
start contacts are operational. High winding and liquid temperature alarm shall be set at
90C (194F) or in accordance with Vendor recommended published data. In absence of
Vendor data, use bolt torque in Table 4.
23. Primary and secondary cables and bus duct shall be properly supported, insulated, and 23
protected against mechanical damage. Bolted connections shall be torqued in
accordance with Vendor recommendations.
24. Check conductor size, insulation class and type for incoming and outgoing cables. 24

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Form 22.10 - Liquid filled transformer inspection checkout (sheet 2 of 2)

LIQUID FILLED TRANSFORMER SLD No SHT 2 of 2


INSPECTION CHECKOUT (Procedure 22.1.9)
DATE: JOB NO: LOCATION: MODULE:
INITIAL/DATE
25. Check conductor phasing and identification. 25
26. Check that conduit connections are tight, sealed, and oriented properly. 26
27. Perform insulation resistance test of transformer primary and secondary windings, 27
and record reading on test record (megger tests).
28. Perform insulation power factor test as required by specs (Doble or equivalent). 28
29. Ensure connections are tight and secure after testing. 29
30. Verify mechanical relief device is reset. 30
31. Verify spare control and alarm conductors are taped or capped, and tagged. 31
32. Verify spare hubs or knockouts plugged with seals intact. 32
33. Verify paint scratches refinished. 33
34. Verify access covers tightly secured, with gaskets in place. 34
35. Vendor representative provided service supervision for this equipment. Vendor test 35
reports shall be attached to inspection record.
36. Final inspection complete. Punch list items cleared. 36
Transformer tap

REMARKS

22.1.10. Lighting and small power distribution systems

22.1.10.1. General
Inspection and test procedures in clause 22.1.10.2 and 22.1.10.3 shall be applicable to lighting,
receptacles, and small power distribution systems.

22.1.10.2. Inspection
a. After installation
1. Equipment shall comply with area classification and specification requirements as
described in design specification and drawings.
2. Location and elevation of lighting fixtures, panel boards, receptacles, and wall
switches shall be compared with approved drawings.
3. Wiring for multivoltage rated lighting fixtures (i.e., combination 230/277/480 volt
sodium vapour fixtures may require field verification).

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4. Distribution panel labelling and circuit numbering shall be verified.


5. Fuse and breaker ratings of circuits shall be compared and verified with approved
drawings.
6. Operation of safety features, such as mechanical interlocks, circuit lockout devices,
and door switches, shall be verified.
7. Verify that distribution panel and power supply cable has been tested and relevant test
certificates completed.
8. Grounding
a) Grounding (earthing) bus bar and wire and cable grounding connections inside
distribution panels shall be inspected for correct installation.
b) Grounding connections from individual items to grounding bus shall be as
detailed on drawings.
c) Grounding bus bar shall be connected to grounding grid in accordance with
NEC.
9. Lighting fixtures, receptacles, and switches shall be inspected for neatness,
weatherproofing, cable connections, terminations, and general good installation
workmanship.
10. Circuit inspection
a) As each branch circuit from distribution panel is inspected, inspection tag shall
be completed and attached in visible position to branch circuit overcurrent
device.
b) Tag shall contain date, circuit number, and inspector name.
11. Equipment in hazardous locations shall be inspected in accordance with
clause 22.1.14.
b. Junction boxes shall be inspected in accordance clause 22.1.17.
c. Inspection checkout forms 22.11 and 22.12 can assist in acceptance of approved
Contractor general test form (GOC form WH EE16, sheet 01).

22.1.10.3. Testing
a. Branch circuit insulation resistance to ground shall be measured in accordance with
Vendor instructions for light fixtures that have electronic systems.
WA shall verify
b. Receptacles
1. Voltage, polarity, and ground continuity of each receptacle shall be verified.
2. Receptacles shall have polarised ground connectors.
WA shall verify
c. Illumination tests
1. Illumination tests shall be performed to ensure compliance with statutory or contract
illumination levels.
2. If illumination levels are not specified, illumination shall comply with NEC.
WA shall peform test
d. Testing of protection and metering circuitry shall be performed as applicable in accordance
with clause 22.1.18.

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WA shall verify
e. Operation of emergency lighting systems and battery capacity shall be tested to sustain
lighting for specified period (i.e., 1 hour).
WA shall perform test

22.1.10.4. Certification
a. Results of illumination level checks shall be recorded on electrical layout drawings and
attached to approved Contractor lighting test form or equivalent (GOC form WH EE16,
sheet 01).
b. Test form shall be endorsed to certify that requirements of clauses 22.1.10, 22.1.14 for
equipment in hazardous loactions, and 22.1.17 for junction box inspection, as applicable,
have been performed satisfactorily.
WA shall verify
c. Originals of test certificates generated in clause 22.1.18 for protective relays and meter
circuits shall be attached to approved Contractor general test form (GOC form WH EE16,
sheet 01).
d. Inspection checkout forms 22.11 and 22.12 shall be attached to certification form listed in
a. above.

Note: If additional light fixtures are linked to existing circuits,


Contractor general test form or equivalent (GOC form WH
EE16, sheet 01) shall be used to document that procedures
in clauses 22.1.10, 22.1.14, and 22.1.17 have been
performed for new lighting fixtures. This avoids need to
retest entire circuit.

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Form 22.11 - Panel board inspection checkout

PANELBOARD SLD No SHT of


INSPECTION CHECKOUT (Procedure 22.1.10)
DATE: JOB NO: LOCATION: MODULE:
TAG NO: __________________ VOLTS: ____________ AMPS: _______________ INITIAL/DATE
1. Receiving inspection complete. 1
2. Check assembly for missing parts. 2
3. Enclosure approved for classification of area installed. 3
4. Panel board circuit schedule correctly filled out and installed. 4
5. Correct circuit breakers installed (including ground fault circuit interruptors [GFCI]) and 5
correct fuse size (if applicable) to comply with drawing schedules.
6. Neutral wire correctly colour coded. 6
MFS Vendor installation
7. Grounding installed and connected (wiring is green colour coded). 7
MFS Vendor installation
8. Seals installed (if required). 8
9. Check for breather and drain (if required). 9
10. Check colour coding of branch circuit conductors. 10
11. Panel board has been cleaned. 11
12. Mounting and supports adequate in compliance with specification and NEC. 12
13. Nameplate voltage and current ratings, number of circuits, and panel board location in 13
compliance with approved drawings.
14. Final inspection complete. Punch list items cleared. 14
Note: See form 22.12 for additional circuit requirements on lighting and receptacles.

REMARKS

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Form 22.12 - Lighting and receptacle inspection checkout

LIGHTING & RECEPTACLE SLD No SHT of


INSPECTION CHECKOUT (Procedure 22.1.10)
DATE: JOB NO: LOCATION: MODULE:
TAG NO: _______________ VOLTS: _____________ AMPS:____________ INITIAL/DATE
1. Receiving inspection complete. 1
2. Check assembly for missing parts. 2
3. Enclosure approved for classification of area installed. 3
4. Panel board and circuit identification referenced. 4
5. Neutral wire correctly colour coded. 5
6. Grounding installed and connected (wiring is green colour coded). 6
7. Seals installed (if required). 7
8. Check for breather and drain (if required). 8
9. Check colour coding of branch circuit conductors. 9
10. Mounting and supports adequate in compliance with specification and NEC. 10
11. Fixtures and receptacles are correct type and in compliance with drawings. 11
12. Fixtures and receptacles on correct circuit and working properly. Receptacle 12
polarity is correct.
13. Ensure tight fit of gaskets on lighting fixtures. Guards and reflectors are 13
fitted and securely fastened in place.
14. Verify minimum lighting levels in compliance with specification and NEC.** 14
15. Verify emergency lighting is functional in compliance with specification.** 15
16. Final inspection complete. Punch list items cleared. 16
Note: ** WA shall perform test.
REMARKS

22.1.11. Neutral grounding resistors

22.1.11.1. General
Inspection and test procedures in clauses 22.1.11.2 and 22.1.11.3 shall be applicable to neutral
grounding resistors.

22.1.11.2. Inspection
a. Before installation
1. Nameplate ratings of grounding resistors shall be verfied with approved drawings.
2. Equipment certificate shall comply with area classification and specification
requirements.
3. Temporary weatherproofing and drying agents (e.g., silica gel) shall be removed.

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b. After installation
1. Neutral grounding resistors shall be inspected for alignment, tightness of foundation
anchor bolts, and supports.
2. Standoff insulators shall be correct type, clean, and undamaged.
3. Cable and conductor connections to neutral grounding resistors shall be correct size
and terminals correctly clamped.
4. Warning labels are required and shall be posted advising sudden high temperature of
resistor in event of ground fault.

22.1.11.3. Testing
a. Insulation resistance
1. Insulation resistance of resistor to ground shall be measured with incoming and
outgoing connections disconnected.
2. 1 000 VDC megger shall be used for 1 minute reading.
3. Value of neutral grounding resistor shall be measured.
WA shall verify
b. Space heater and connecting circuits, if installed, shall be tested.
WA shall verify
c. Current transformers
1. Current transformers, if installed, shall be checked against Vendor test certificates and
magnetising curves.
2. If certificates and curves are not available, applicable tests in clause 22.1.16 for
instrument transformer verification shall be performed.
WA shall verify
d. Grounding
1. Equipment ground path resistance at main grounding terminal to system ground shall
be measured and recorded.
2. Value shall be less than 2 ohms from resistor connection to ground, including ground
electrode.
WA shall verify
e. Applicable testing of protective relays and meter circuitry in accordance with
clause 22.1.18 shall be performed.
WA shall verify
f. Upon completion of tests, incoming and outgoing cables to bushing, resistor, and resistor
to ground grid shall be reconnected.
WA shall verify

22.1.11.4. Certification
a. Approved Contractor neutral grounding resistor test form (GOC form WH EE7, sheet 01)
shall be completed and endorsed to confirm that requirements of clause 22.1.11 have been
performed satisfactorily.
b. Supporting Vendor test certificates for current transformer certificates shall be supplied in
Vendor data book that forms part of project dossier.

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c. Vendor test certificates that are shipped loose should be attached to approved Contractor
neutral grounding resistor test form (GOC form WH EE7, sheet 01), together with
originals of test certificates generated in clause 22.1.18 for protective relays and meter
circuitry.

22.1.12. Heat trace cables and circuits

22.1.12.1. General
Following inspection and test procedures in clauses 22.1.12.2 and 22.1.12.3 shall be applicable
to heat traced cables and circuits.

22.1.12.2. Inspection
a. Before installation
1. Supplied heater cable shall be correct as noted on design drawings and correctly rated
for area classification where installed.
2. Heater cable shall be correct length.
3. Circuit shall be correct for voltage and power rating of heater cable.
4. Continuity and insulation tests
a) Continuity and insulation tests shall be performed while cable is on reel.
b) Test results shall be recorded on approved Contractor electrical heat trace
performance test form (GOC form WH EE8, sheet 02).
b. After installation
1. Fuse or breaker rating shall be correct for total circuit loading.
2. Heater cable shall be correctly installed, especially concerning high point vents, low
point drains, dead legs, flanges, and removable items, such as valves and instrument
or control devices.
3. Mounting and grounding of junction boxes and thermostats shall be correct.
4. Devices, such as separately mounted controllers, sensors, and mounting materials,
shall be grounded in accordance with applicable codes.
5. Inspection and tests shall be performed, as applicable, in accordance with
clauses 22.1.4 for power, control and instrument cables, 22.1.14 for equipment in
hazardous locations, and 22.1.17 for junction box inspection.
6. Insulation resistance measurements shall be performed:
a) While heater cable is on reel.
b) After initial installation.
c) After completion of piping or vessel insulation.
c. Inspection checkout and inspection form 22.13, sheets 1 and 2, shall be used to assist in
acceptance of equipment as documented on following:
1. Heat trace tape inspection form (GOC form WH EE8, sheet 01).
2. Electrical heat trace performance test form (GOC form WH EE8, sheet 02).

22.1.12.3. Testing
a. After installation is complete, each heater cable shall have insulation resistance test using
500 V megger in accordance with clause 22.1.4.
WA shall verify
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b. After heater cables on circuit are installed, complete circuit shall have insulation resistance
test and results shall be recorded.
WA shall verify
c. After installation of thermal insulation, circuit shall have insulation resistance rechecked to
ensure no damage has occurred.
WA shall verify
d. Performance test
1. Heat trace system shall be performance tested at following intervals:
a) At startup.
b) After 10 minutes.
c) After 4 hours.
2. Test results shall be recorded on approved Contractor electrical heat trace
performance test form (GOC form WH EE8, sheet 02).
WA shall perform test
e. Heat trace failure alarm
1. Commissioning authority shall perform functional checkout of heat trace failure
alarm.
2. Test results shall be recorded on approved Contractor system control function test
form (GOC form WH SC1).

22.1.12.4. Certification
a. Approved Contractor forms shall record and certify test results and shall be endorsed to
confirm that requirements in clause 22.1.12 have been performed satisfactorily:
1. Heat trace tape inspection form (GOC form WH EE8, sheet 01).
2. Electrical heat trace performance test form (GOC form EE8, sheet 02).
3. Cable and wire insulation resistivity form (GOC form WH EE1, sheet 02) for cable
testing in accordance with applicable procedures in clause 22.1.4.
b. Forms shall require endorsement to confirm that procedures clauses 22.1.12, 22.1.4,
22.1.14, and 22.1.17, as applicable, have been performed satisfactorily.
c. Inspection checkout and inspection form 22.13, sheets 1 and 2, shall be attached to
certification forms listed in a. above.

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Form 22.13 - Heat trace component inspection checkout (sheet 1 of 2)

HEAT TRACE COMPONENTS SLD No SHT 1 of 2


INSPECTION CHECKOUT (Procedure 22.1.12)
DATE: JOB NO: LOCATION: MODULE:
Line Number Heater Number Service
Manufacturer Model/Cat. Number Voltage Wattage
Watts/Foot
Construction inspection - general INITIAL/DATE
1. Inspect control panel to ensure proper installation in accordance with 1
drawings and specifications. Check circuit breaker ratings and fuse ratings.
2. Verify that installation and connection of temperature controller is in 2
accordance with Vendor instructions and wiring diagram and in accordance
with project approved drawings.
3. Inspect entire assembly for damage and missing parts. 3
4. Verify that heat tracing cable ends are properly protected from physical 4
damage and moisture contamination.
5. Inspect for apparent damages such as cuts, cracks, or moisture spots. 5
6. Verify that heat tracing cables have tin plated copper grounding braid and 6
Teflon outer jacket or equivalent. Verify catalogue type, wattage, voltage
rating, and area classification ratings are correct.
7. Verify that grommets, connection boxes, end seals, and other connection 7
hardware are correct type and size in accordance with Vendor drawings and
project approved drawings, as applicable.
8. Verify heat tracing power connection, splicing, and wiring colour code to 8
ensure that phase connections are correct in accordance with drawings,
proper connection hardware is used as shown in drawings, connection boxes
are installed on upper quadrant of pipe, and heat shrink boots instead of
electrical tape are used for insulating heat trace core material.
9. Verify that armoured cables for power feeders are adequately supported. 9
10. Verify that heat trace power supply panels have correct breaker ratings 10
including needed GFCIs.
REMARKS

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Form 22.13 - Heat trace component inspection checkout (sheet 2 of 2)

HEAT TRACE COMPONENTS SLD No SHT 2 of 2


INSPECTION SUMMARY (Procedure 22.1.12)
DATE: JOB NO: LOCATION: MODULE:
Line Number Heater Number Service
Manufacturer Model/Cat. Number Voltage Wattage
Watts/Foot
Power connections, splices, and tees INITIAL/DATE
1. Power to heater connections, heat trace splices, and tees shall comply with 1
design drawings and correct voltage source.
2. Changes shall be recorded on as built drawings. 2
3. Correct identification tags shall be installed. 3
4. Junction box and lid gaskets shall be correctly installed. 4
5. Proper grommets shall be installed. 5
6. Outer jacket shall extend completely through grommet (CT heaters). 6
7. Shield pigtail shall be tight (no loose strands or whiskers). 7
8. 1/2 in minimum distance between shield and inner jacket cutback. 8
9. Heater bus wires properly stripped (no loose or broken strands). 9
10. Heater bus wires insulated up to terminal block (Note: Electrical tape is not 10
acceptable. Only heat shrink material is acceptable).
11. Three phase connections in accordance with Vendor colour code. 11
Transmitter end terminations INITIAL/DATE
1. Correct identification tag installed on each unit. 1
2. Proper sealing gasket installed between transmitter box and base. 2
3. Proper grommets installed. 3
4. Outer jacket extends completely through grommet (CT heaters). 4
5. Bus wires properly connected to transmitter: 5
a) Insulated with heat shrinkable tubing.
b) #14 AWG insulated wire with butt splice properly crimped.
6. 1/2 in minimum distance between shield and outer jacket cutback. 6
7. Heater shield properly insulated with heat shrink tubing. 7
8. Heater shield connected to resistance temperature detector (RTD) shield (or 8
green wire) with properly crimped wire joint.
9. Monitor wire cutback, if present (not to be used). 9
REMARKS

22.1.13. Grounding and bonding

22.1.13.1. General
Inspection and test procedures in clauses 22.1.13.2 and 22.1.13.3 shall be applicable to
grounding and bonding.

22.1.13.2. Inspection after installation


a. Ground connection type and size shall be verfied with schedule, drawings, and
specifications.
b. Conductor material shall comply with specifications.
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c. Crimped terminations
1. Conductors, if terminated with crimped connections, shall have correct size and type
of crimped connection.
2. Crimp tool shall be listed for use with compression lugs and shall be ratchet type that
releases only after complete compression.
3. Compression applied connectors shall be inspected for correct cable match and
indentation.
d. Grounding
1. Ground rod in ground well shall be accessible.
2. Grid wire sizes and colour identification shall comply with drawings and
specifications.
3. Underground splices and internal foundation ground connections shall be inspected.
e. Connections shall be tight, with antioxidising grease applied to terminations.
f. Metal assemblies, conduits, and junction boxes shall be properly bonded together and
bonded to ground.

22.1.13.3. Testing
a. Grounding tests
1. Each separate grounding point (that may consist of one or more electrodes) shall be
verified with ground resistance instrument that is certified for accuracy to 1 ohm or
less.
2. Resistance of each point shall not exceed following:
a) Electrical grounding: 1 ohm.
b) Lightning protection: 7 ohm.
c) Static bonding: 10 ohm.
b. If required by authority in charge, fall of potential test for soil resistance in accordance
with IEEE 81, section 9.04, shall be performed.
WA shall verify
c. Two point method test in accordance with IEEE 81, section 9.03, shall be performed to
determine ground resistance between grid connected grounding electrode and major
electrical equipment frames, system neutral, or derived neutral points.
d. Alternate method to c.; ground continuity test may be performed as follows:
1. Test shall be performed between grounding electrode and equipment frame, system
neutral, and/or derived neutral point.
2. Minimum of 10 amp DC current shall be passed between grounding electrode (at
system grid) and ground point to be tested.
3. Voltage drop shall be measured and resistance shall be calculated by voltage drop
method.
e. Tests shall be performed to ensure that resistance as measured from any part of system to
main ground grid shall not exceed following values:
1. Electrical grounding: 1 ohm.
2. Lightning protection: 7 ohm.
3. Static bonding: 10 ohm.
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22.1.13.4. Certification
Following approved Contractor forms shall be used for recording test results and shall be
endorsed to confirm that requirements in clause 22.1.13 have been performed satisfacitorily:
a. Ground system test form (GOC form WH EE9, sheet 01).
b. Grounding resistance test form (GOC form WH EE9, sheet 02).

22.1.14. Equipment in hazardous locations

22.1.14.1. General
a. Following inspection and test procedures in clauses 22.1.14.2 and 22.1.14.3 shall be
applicable to all types of equipment in hazardous locations or specified accordingly and
installed in safe areas.
b. This clause is general inspection guide for all types of equipment installed in classified
(hazardous) locations or specified and installed in unclassified locations.
c. Specific requirements for special equipment in these locations shall be listed individually
and should be read in conjunction with following:
1. GP 12-60.
2. NFPA 70 (NEC), sections 500, 501, and 505.
3. Appropriate national or regional standards.

22.1.14.2. Inspection
a. After installation
1. Equipment classification
a) Equipment shall be listed and labelled for use in proper installed area
classification.
b) Surface temperature (T rating) shall be correct.
c) Special Vendor considerations shall be confirmed and accepted by WA as
applicable.
d) No unauthorised modifications shall be performed to equipment.
2. Mechanical
a) Equipment shall not be damaged and shall be adequately protected against
corrosion, weather, vibration, and other adverse factors pertaining to installation.
b) Bolts, cable terminations, conduit seals, and plugs shall be secured and wrench
tight.
c) Enclosure gaskets shall be installed and in good condition.
d) Equipment interior shall be inspected and cleaned to remove dust or dirt.
3. Electrical
a) Electrical connections shall be tight.
b) Protection shall be adequate for equipment rating.
c) Electrical cables shall be inspected for distress or damage.
d) Equipment grounding shall be inspected for integrity.
e) Joints shall be properly tightened.
f) Lamp ratings and types shall be correct for installed lighting fixtures.
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4. Conduit seal
a) As applicable, cable and conduit sealing compound shall be correctly applied to
avoid ingress of hazardous material.
b) Seal packing shall be inspected to ensure adequate separation of conductors,
with seal compound filling spaces between.
c) Compound shall be installed in accordance with Vendor specifications.
5. Guards, if used, shall be correctly located and secure.
6. Motor fans and couplings shall not rub or contact housings or guard covers.
b. Classified enclosures (Class I, Division 1, Division 2, or Zone equivalent)
1. Path of door openings or air ventilation around equipment shall not be blocked or
impeded.
2. Cover door gaps (in accordance with machining tolerance) shall be correct and free
from corrosion, dirt, and paint.
3. Bolt holes shall be filled and bolts shall be in place and tight.
4. Conduit runs shall be wrench tight, free from corrosion, and comply with NEC 500,
NEC 501, and NEC 505.
5. Unused conduit stubs or openings for fittings shall be plugged and sealed.

Note: Spare conduits shall be sealed off as if they had wiring.

c. Intrinsically safe installations (see NEC 504)

Note: Equipment used as intrinsically safe shall be so labelled


and certified to meet standard.

1. Cable or wiring shields shall be grounded in accordance with relevant standard


drawings. Floating shields are not allowed.
2. Diode safety barrier installations shall:
a) Be correct type.
b) Remain firmly fixed to barrier ground bus.
3. Boxes containing diode safety barriers and junction boxes shall not contain wiring
other than that specified in documentation for intrinsically safe system.
4. Intrinsically safe wiring shall be separated from non intrinsically safe wiring.
5. Relays and similar devices that act as safety barriers between circuits shall not
become damaged by repeated operation or mechanical vibration (such damage may
reduce separation and cause loss of intended safety).
6. Ground path resistance shall be measured from safety barrier to certified grounding
conductor.
d. Purged or pressurised equipment (see NEC 500 and NFPA 496)
1. Purge medium shall be from uncontaminated source that is isolated from hazardous
material.
2. Filters shall be clean, accessible, and approved for area and enclosure.
3. Only inline filters shall be permitted.

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4. Purge pressure, cycle times, interlocks, lockout sequence, and alarm provisions shall
be intact and operating properly.
5. Purged pressurised equipment shall comply with NFPA 496.
e. Grounding of any classified equipment shall comply with following:
1. NEC article 250.
2. NEC articles 500 through 505 as applicable.

22.1.14.3. Testing
a. Diversity of equipment and special components contained in particular type of equipment
does not permit generalisation of testing required to demonstrate suitability for service in
hazardous location.
b. Special requirements for testing that may be in GP 12-60 or specific IEEE standards shall
be compiled before final energisation of circuit.
c. Vendor documentation shall be examined to ensure that electrical components and
equipment are listed and labelled for specified use as required by NEC, UL, FM, or
appropriate NRTL standards.
d. Certificates shall be examined to determine whether validity of certificate is subject to
specific installation instructions and further testing after installation (e.g., testing cables for
intrinsically safe equipment).

22.1.14.4. Certification
a. There is no specific standard form for recording that requirements of clause 22.1.14 have
been implemented.
b. Approved Contractor hazardous locations test form (GOC form WH EE10, sheet 01) shall
be used to record test results and shall be endorsed as required by:
1. Clause 22.1.14.
2. GP 12-60.
3. IEEE standards.
4. Applicable NRTL standards.
c. Certificates necessary for approval by WA refer to requirement that equipment be certified
as approved for area classification in which it is installed.
The following clauses refer to procedures in this clause and may require approved
Contractor hazardous locations test form (GOC form WH EE10, sheet 01), to be
attached to forms (GOC forms noted in parenthesis) generated by the clauses, to
signify equipment and standard of installation is suitable for use in hazardous areas.
Clause Title
22.1.4 Power, control, and instrument cables (GOC form WH EE 1, sheet 01,
02, and 03).
22.1.5 Switchgear, motor control centres, and metal enclosed bus duct (GOC
form WH EE2, sheets 01 and 02).
22.1.6 Circuit breakers - air, moulded case, vacuum, and oil immersed
(GOC form WH EE3, sheets 01, 02, 03, and 04).
22.1.7 Contactor starters (GOC form WH EE13, sheet 01).
22.1.8 Medium voltage air switches GOC form WH EE5, sheet 01).

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22.1.10 Lighting and small power distribution systems (GOC form WH EE16,
sheet 01).
22.1.12 Heat trace cables and circuits GOC form WH EE8, sheets 01 and 02).
22.2.6 AC induction synchronous motors (GOC form WH EE13, sheets 01
and 02).
22.2.7 AC generators (GOC form WH EE18, sheets 01 and 02).
22.2.8 Variable speed drives (GOC form WH EE4, sheet 03).
22.2.11 Navigation aids (GOC form WH EE17, sheet 01).

22.1.15. Oil insulation tests

22.1.15.1. General
Following inspection and test procedures shall be applicable to oil insulation tests.

22.1.15.2. Testing
a. If new projects have oil filled electrical equipment in work scope, separate procedure for
oil filled electrical equipment shall be produced.
b. If project interfaces with existing oil filled equipment, local site procedures shall be used.
c. See clause 22.1.9 for transformer oil testing requirements.

22.1.15.3. Certification
a. There is no specific standard form for recording that procedures in clause 22.1.15 have
been implemented.
b. Approved Contractor general test certificate (GOC form WH EE16) shall be used to record
test results and shall require endorsement to confirm that procedures of clause 22.1.15 have
been performed satisfactorily for oil insulation tests.
c. Approved Contractor general test certificate along with transformer oil insulation test
results shall be attached to power transformer test form produced in clause 22.1.9.

22.1.16. Instrument transformer verification

22.1.16.1. General
Inspection and test procedures in clauses 22.1.16.2, 22.1.16.3, and 22.1.16.4 shall apply to
instrument transformers.

22.1.16.2. Inspection after installation


a. Nameplate
1. Nameplate on current transformers (CT) shall be checked to ensure that it indicates
correct class, type, and ratio for duty in compliance with project IFC and Vendor
drawings.
2. Nameplate shal be mounted in correct location in accordance with drawings details.
b. CT installation
1. CT mounting brackets shall be securely fixed.
2. CTs shall be inspected for transportation damage.
3. CTs shall have adequate clearance from moving parts of switchgear.
4. CTs shall be clear of possible interference with cables scheduled for installation in
switchgear.
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c. Electrical
1. Electrical polarity marks shall be visible on CT and potential transformers or shall be
shown on transformer nameplates.
2. CTs shall have accessible secondary shorting terminal blocks.
3. Terminal blocks shall remain in shorted position until circuits are complete.
4. CT secondary wiring shall be terminated in short circuiting type terminal strips that
are accessible to technicians.

22.1.16.3. Testing
a. Preliminary
1. Before testing begins, primary circuit shall be open circuited.
2. In most cases, this can be achieved by disconnecting outgoing and incoming cables
and opening breaker or switch.
3. Exposed primaries shall have protection because dangerously high voltages are
produced during testing.
b. For both CT and PT, insulation resistance of transformer secondary winding and leads
shall be measured with 1 000 V megger with ground lead lifted and electronic devices
protected.
WA shall verify
c. Transformer primary insulation overpotential shall be measured with proper Vendor
voltage and procedure.
WA shall verify
d. CT secondary wiring
1. CT secondary lead wiring shall be verified by connecting low current through leads
and taking readings at applicable relaying and metering devices connected to
transformer secondary circuit.
2. Low range clamp on ammeter may be used to read currents.
WA shall verify
e. PT secondary wiring
1. Primary PT fuses shall be pulled.
2. Wiring of PT secondary leads shall be checked by applying low voltage to leads and
checking for this voltage at potential input terminals of metering and protective
devices.
3. Primary PT fuses shall be replaced.
WA shall verify
f. kVA load
1. PT circuits shall be fully energised.
2. PT kVA load shall be checked with secondary voltage and current measurements as
required.
3. Load shall be less than VA capacity of PT.
WA shall verify
g. CT magnetising characteristics

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1. Testing to determine magnetising characteristics of CTs shall be performed by


Vendor after assembly.
2. Vendor test certification shall be checked for completeness and accuracy.
3. ANSI characteristics shall be supplied by certified test data from Vendor.
4. If certified data is not available, WA may require removal and certified bench testing
to be performed.
5. Testing in 4. shall not be required onsite.
6. If certified CT test data is not presented, Vendor shall provide certified data, perform
tests, or secure services to do so, subject to BP approval.
WA shall verify

22.1.16.4. Test procedure


a. Magnetising curve testing shall be performed by Vendor.
b. Testing shall only be required if insufficient certified test data are provided with
equipment.
c. PT and CT ratio
1. Ratio of PTs and CTs may be performed with variable voltage or variable current
sources commonly available with portable test sets for metering or protective relay
checks.
2. Testing in 1. shall not substitute for certified test data.

22.1.16.5. Certification
Approved Contractor instruments transformer ratio test form (GOC form WH EE11, sheet 01)
shall record results of ratio testing and shall be endorsed to confirm that requirements of above
procedures in clause 22.1.16 have been performed satisfactorily.

22.1.17. Junction box inspection

22.1.17.1. General
Inspection and test procedures in clauses 22.1.17.2 and 22.1.17.3 shall be applicable to junction
boxes.

22.1.17.2. Inspection after installation


a. Junction box location shall be correct in accordance with IFC drawings.
b. Junction box shall be suitable and certified for area classification specified.
c. Junction box shall be adequately supported and permanently labelled for cable
identification, drawing numbers, and source location.
d. Junction box identification
1. Internal terminal types, sizes, support, and identification shall be correct, listed, and
labelled for use specified.
2. Wiring shall be properly tagged and colour coded in accordance with specifications
and drawings.
e. Grounding connections (both internal and external) shall be correct and tight.
f. Cable terminations

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1. Cable terminations on terminals shall be checked with calibrated torque wrench in


compliance with Vendor published data.
2. In absence Vendor data in 1., torque values in Table 4 shall be used.
g. Cable terminations and accessories shall be correctly installed, with unused cable entries
plugged and sealed in accordance with area classifications.
h. Gaskets, if required, shall be correctly installed and properly lubricated to preserve gasket
quality.
i. Box covers shall be correctly sealed, with bolts, latches, and clamps in place and tight.
j. For hazardous area locations, procedures in clause 22.1.14 shall be followed.

22.1.17.3. Testing
Testing of junction boxes is not required, with exception that ground (earth) continuity test shall
be performed and results shall be logged in inspection checkout.

22.1.17.4. Certification
a. There is no specific standard form for recording that procedures in clause 22.1.17 have
been performed.
b. Following approved Contractor test forms refer to procedures in clause 22.1.17 and require
endorsement to confirm that junction boxes and standard of installation is suitable for
intended service:
1. Electrical power, control, and instrument cable test forms (GOC form WH EE1
sheets 01 through 04). See clause 22.1.4.
2. Heat tracing test forms (GOC form WH EE8, sheets 01 and 02). See clause 22.1.12.
3. General test certificate (GOC form WH EE16, sheet 01) for form 22.1.11 panel board
inspection checkout. See clause 22.1.10.

22.1.18. Protective relay and metering circuit testing

22.1.18.1. General
a. Procedures in clauses 22.1.18.2 and 22.1.18.3 shall be applicable to protective relays and
metering circuits.
b. Equipment covered by following procedures may require testing of protective relays or
meter circuitry by primary or secondary injection as specified by WA.
c. Approved Contractor primary injection or secondary injection test report forms (GOC form
WH EE12, sheets 01 and/or 02) shall be used for recording results of primary and
secondary injection testing.
d. Following sections may require testing of protection and meter circuitry by primary or
secondary injection:

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Clause Title
22.1.5 Switchgear, motor control centres, and metal enclosed bus duct
22.1.6 Circuit breakers - air, moulded case, vacuum, and oil immersed
22.1.7 Contactor starters
22.1.8 Medium voltage air switches
22.1.9 Power transformers - oil filled and dry type
22.1.10 Lighting and small power distribution systems
22.1.11 Neutral grounding resistors
22.2.6 AC induction synchronous motors
22.2.7 AC generators
22.2.8 Variable speed drives
22.2.9 Batteries and battery chargers
22.2.10 Uninterruptible power supplies

22.1.18.2. Inspection
For each type of relay or meter tested, approved Contractor relay inspection report form, (GOC
form WH EE12, sheet 03) shall be used to record inspection of relay and associated
components.
WA shall verify

22.1.18.3. Testing
a. Because of variety of schemes and diverse types of relays in use, no attempt has been made
to produce standard testing procedure.
WA shall verify
b. Relay tests shall be performed by or under supervision of qualified electrical engineer
(typically from specialty Contractor or technical testing service equipped and experienced
to perform work).
c. Each protective relay shall be inspected, tested, tagged, and dated by service company
performing work.
d. Records on relay and meter tests shall be completed and made part of equipment certificate
record for that equipment.
e. Relay test certificates shall be required for each protective relay in accordance to
application type per approved Contractor relay test report forms (GOC form WH EE12,
sheets 04 through 10).

Note: If relay is type not covered by Contractor or GOC forms,


installer/tester shall provide suitable form with typical format.
It may also be expedient to use one furnished form by
changing title and adding new sheet numbers.

WA shall verify

22.1.18.4. Certification
a. Following approved Contractor forms shall be used, as appropriate, for recording results of
primary and secondary injection testing for protective relays and meter circuitry, along
with calibration readings and endorsed by WA to confirm that requirements of
clause 22.1.18 have been performed satisfactorily:
1. Primary injection test report (GOC form WH EE12, sheet 01).

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2. Secondary injection test report (GOC form WH EE12, sheet 02).


3. Contractor general test form (GOC form EE12) may be used as continuation sheet, if
required.
b. Approved Contractor relay inspection form (GOC WH EE12, sheet 03) shall be used for
recording inspection results of relays and associated components and endorsed by WA to
confirm that inspection has been satisfactorily performed.
c. Approved Contractor relay test report forms (GOC form WH EE12, sheets 04 through 10)
shall be used for certifying protective relay testing and calibration, with endorsement to
confirm that requirements of clause 22.1.18 have been performed satisfactorily.

22.1.19. Cathodic protection (CP) systems

22.1.19.1. General
a. Inspection and test procedures in clauses 22.1.19.2 and 22.1.19.3 shall be applicable to CP
systems.
b. CP systems shall comply with GP 06-31, GP 06-32, and GIS 06-311.
c. Installation shall be carried out under supervision of competent person, to ensure
installation is in accordance with relevant drawings, specifications, and procedures.
d. CP should be applied to wide variety of production and process equipment, onshore and
offshore, including (but not limited to) following:
1. Onshore:
a) Above and below ground storage tanks and vessels.
b) Buried process and utility pipelines.
c) Well casings.
d) Shell and tube heat exchangers using cooling water.
e) Buried/immersed structures.
2. Offshore:
a) Fixed and floating production facilities.
b) Drilling fluid storage tanks.
c) Subsea systems, e.g. well-heads, risers, mooring systems, flowlines and
pipelines.
d) Firewater and sea water pump caissons.
e) Coastal/marine terminals, e.g. wharfs, jetties, mooring and breasting dolphins.
e. CP systems may be passive or active system:
1. Galvanic (sacrificial) anode system.
2. Impressed current system.

22.1.19.2. Inspection
a. Galvanic anode system
1. Before installation
a) Anode shall be verified that it is proper alloy material for application and meet
specification requirements.

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b) Groundbed material shall be verified for proper material composition and meet
specification requirements.
2. Installation
a) Galvanic anodes shall be installed in such way that even current distribution is
achieved and allows each element of the structures surface to reach protection
potential.
b) The underside of stand-off anodes should be installed 300 to 350 mm (12 in to
14 in) from cathode surface.
c) Flush mounted anodes should only be used for fabrications in which space
limitation prevents use of stand-off anodes or if cathode current densities are
low.
d) For onshore pipelines, galvanic anodes should be installed separately or in small
groups at intervals of 30 m to 200 m (100 ft to 700 ft). Spacing depends on
current demand from pipeline and current provided by individual anodes.
e) Anodes should be buried just below pipeline, close to pipeline.
f) Insert design shall accommodate anode weight and the forces likely to be
encountered during its lifetime, including installation, impact, storm damage,
wave action, and ice flows.
g) Stand-off and flush mounted anode types should be welded directly to structure
surface or to steel doubler plates pre-welded to the structure.
h) Bracelet anodes should be fitted around pipeline and bolted or welded together.
i. Electrical continuity between anode bracelet insert and pipeline should be
provided by cable tails pre-attached to insert.
ii. Each bracelet should have at least two bonding leads attached.
iii. Cable tails should be connected to pipeline or riser using thermite welds or
pin brazed connections.
i) For onshore pipelines, anode cable tail should be brought into test post at surface
and be connected to pre-attached cable from pipeline.
Alternatively, bracelet anode inserts can be supplied with steel extension bar that is
welded to doubler plate pre-installed on pipeline.
j) Connection of anode insert to structure or cable shall become part of protected
structure and receive protective current.
k) Anodes shall be set in groundbed material and groundbed material filled to
recommended height.
l) CP warning tape shall be laid above groundbed prior to filling with backfill to
restore land.
m) Test station shall be checked to ensure that the test leads are of correct size and
properly terminated.
3. Testing
a) Continuity test shall be performed between the structural components (i.e. piping
or tank) and the galvanic anode system.
b) Electrical continuity across connections (i.e. flanges) shall be checked.
c) Continuity test shall be performed on flange insulation kit, if installed, to ensure
isolation.

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d) Current output readings shall be taken and shall be recorded to ensure that CP
system is working properly.
e) Type of test equipment shall be recorded on test forms.
b. Impressed current anode system
1. Before installation
a) Anode shall be verified that it is proper alloy material for application and meet
specification requirements.
b) Anodes shall have factory encapsulated cable connections.
c) Groundbed
i. Proper material composition shall be verified.
ii. Minimum site distance should be 100 m (330 ft) from structure. Complex
structures (i.e. multiple buried lines) may require distribution of smaller
groundbeds individually placed closer to structure.
2. Installation
a) Impressed current CP system should be installed as simultaneously as structure
to be protected is installed.
b) Anodes installation shall be checked to ensure that even current distribution is
achieved and allows each element of the structures surface to reach protection
potential.
c) Anodes shall be set in groundbed material and groundbed material filled to
recommended height.
d) Anodes installed in deepwell or borehole groundbeds should have plastic vent
pipe to prevent gas build-up.
e) Reference electrode shall be installed to measure structure potential and control
output of transformer rectifier.
f) Reference electrodes should not have direct contact with steel structure.
g) Buried cable connections shall be fully encapsulated and water tight.
h) If possible, connections shall be made above ground in connection pillar or
anode junction box.
i) Surface connection boxes should be designed to resist tampering, theft, or
vandalism.
j) Junction boxes shall meet required electrical classification of area installed.
k) Junction boxes shall be inspected in accordance with clause 22.1.17.
l) Pipeline installations
i. Insulated conductor shall be attached to pipeline and shall be terminated to
test post or surface terminal box.
ii. Test posts should at one kilometre interval along pipeline route.
m) Buried tanks or above ground storage tank bases
Same requirements shall apply as for pipelines.
n) Onshore pipeline connections
i. Negative header cable from the pipeline shall be connected to structure
terminal in rectifier.

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Draft 20 April 2007 GP 32-20
Site Inspection, Testing, and Commissioning of Plant and Facilities

ii. Positive header cable from the anodes shall be connected to anode terminal
in rectifier.
o) Connection of anode insert to structure or cable shall become part of protected
structure and receive protective current.
p) CP warning tape shall be laid above groundbed and anode header cable prior to
backfilling to restore land.
q) Test station shall be checked to ensure that header cables are of correct size and
properly terminated.
r) Intrinsically safe installations (see NEC 504)

Note: Equipment used as intrinsically safe shall be so labelled


and certified to meet standard.

i. Cable or wiring shields shall be grounded in accordance with relevant


standard drawings. Floating shields are not allowed.
ii. Intrinsically safe wiring shall be separated from non-intrinsically safe
wiring.
3. Testing
a) Electrical continuity shall be checked between the structural components and the
galvanic anode system.
b) Current output readings shall be taken and shall be recorded to ensure that CP
system is working properly.
c) Type of test equipment shall be recorded on test forms.
d) Rectifier power cables
i. Onsite installed cables shall be inspected and tested in accordance with
clause 22.1.4.
ii. Inspection and test results shall be documented on approved Contractor
cable test forms (GOC form WH EE1, sheets 01 and 02).
e) Intrinsically safe installations (see NEC 504)
Equipment installed on site for hazardous locations shall be inspected and tested
in accordance with clause 22.1.14.
f) Transformer rectifiers
Transformer rectifiers shall be inspected and tested in accordance with
clause 22.1.9 for transformers.

22.1.19.3. Certification
a. No specific forms are available for this procedure, but approved Contractor cathodic
protection system test form or general test form (GOC form WH EE16) shall be completed
and endorsed to confirm that requirements of clauses 22.1.19, 22.1.4 for cables, 22.1.9 for
power transformers, 22.1.14 for hazardous locations, 22.1.17 for junction box inspection,
as applicable, have been performed satisfactorily.
b. Any documentation supplied by CP installer shall be attached to Contractor test form.
c. Sketch or drawing of CP systems shall be included with Contractor test form.

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Draft 20 April 2007 GP 32-20
Site Inspection, Testing, and Commissioning of Plant and Facilities

22.2. Commissioning

22.2.1. General
Before commissioning activities begin on system, following shall be completed and signed off
by construction and commissioning authorities on approved Contractor forms:
a. MC certificate (GOC form MC1).
b. Punch list (GOC form PL1).

22.2.2. Energisation and commissioning


a. Commissioning requirements
1. While outside scope of this GP, commissioning requirements dictate sequence and
program for electrical testing.
2. BP site electrical engineer shall be responsible for liaison with commissioning to
achieve integrated program.
3. Handover for commissioning is normally by system or part system as defined by
commissioning group.
4. Definitions of system or part system may differ in some detail from those of design
Contractors.
5. BP site electrical engineer shall be responsible for agreeing upon precise system
limits with commissioning before commencement of testing.
b. Energisation
1. Construction shall notify WA that work is complete and arrangements shall be made
to energise circuit at mutually convenient time.
2. Energisation and commissioning of circuit shall be performed by and shall be
responsibility of commissioning authority and operator electrical supervisor as
follows:
a) Up to 480 VAC, by commissioning authority.
b) Over 480 VAC, by operator electrical supervisor.
c. Energisation requirements
1. Under no circumstances shall circuit be energised or commissioned before circuit is
inspected and tested.
2. Relevant certificate as identified on appropriate ITS shall be completed and approved.
3. Permit to work shall be obtained before initial energising.
d. Test requirements
1. Tests shall be performed on cables or equipment with agreement and presence of
representative of construction authority or WA.
2. If results of tests and checks performed after energisation are not satisfactory, circuit
shall be deenergised, locked out, and handed back to construction authority for
remedial action.
3. Required tests and checks shall be completed and accepted before equipment can be
energised for service.
4. See clause 22.1.3.2 for details on when WA shall perform or verify test.

Downloaded Date: 6/17/2008 10:43:50 PM


The latest update of this document is located in the BP ETP and Projects Library
Page 207 of 366
Draft 20 April 2007